Photovoltaic junction box lead processing junction box installation welding method and all-in-one machine

Abstract

The application discloses a kind of photovoltaic junction box lead processing junction box installation welding method, the installation welding method is realized by photovoltaic junction box lead processing junction box installation welding integrated machine, the photovoltaic junction box lead processing junction box installation welding integrated machine includes lead processing backplate gluing integrated machine, junction box installation integrated machine, junction box laser welding machine, the installation welding method includes the following steps: step one: photovoltaic module is sent to the inside of lead processing backplate gluing integrated machine, tear glue, straighten, glue is applied;Step two: junction box is fed by junction box installation integrated machine, busbar is positioned, shaped, and busbar is installed with junction box;Step three: photovoltaic module enters junction box laser welding machine, after completing center positioning, first photographing, second photographing is carried out, and then welding is carried out.The application integrates photovoltaic junction box lead processing, installation welding as a whole, and the degree of automation is high, and the accuracy is high.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic junction box technology, and in particular to a photovoltaic junction box lead processing, junction box installation and welding method and integrated machine. Background Technology

[0002] The photovoltaic industry has huge development potential. Solar energy is an important part of renewable energy, and photovoltaic modules are the core components of photovoltaic power plants. The photovoltaic module junction box plays a very important role in photovoltaic modules.

[0003] On photovoltaic (PV) module production lines, before the PV modules enter the lamination process, a piece of high-temperature tape is placed at the perforation of the backsheet to prevent EVA from overflowing after melting. After the modules exit the laminator, the high-temperature tape adheres to the backsheet due to contact with the EVA adhesive. Before installing the junction box, the high-temperature tape must be removed. Then, after the PV module busbars are straightened, the junction box with adhesive applied to its back is passed through the vertical busbars and pressed onto the PV module backsheet. Currently, on the production line, this is done manually by forcefully tearing off the tape with needle-nose pliers and manually applying adhesive to the back of the junction box before installation. However, manually tearing off the high-temperature tape and applying adhesive to the junction box is labor-intensive, inefficient, and increasingly difficult to remove and install as PV module sizes may increase. Furthermore, applying adhesive to the back of the junction box can easily cause adhesive drips onto the PV module backsheet, adversely affecting subsequent production.

[0004] Furthermore, before photovoltaic modules enter the busbar welding process, the busbars are threaded through the junction box holes and then bent and fitted onto the junction box welding surface. Currently, on the production line, this is mostly done manually by two people threading the busbars and then bending and fitting them onto the junction box welding surface. As photovoltaic module sizes may increase with each iteration, the shaping difficulty will rise, making manual assembly increasingly difficult. At the same time, the disorganized placement of junction boxes in different locations will affect manual selection and impact production efficiency.

[0005] Furthermore, most photovoltaic junction box feeding and conveying machines currently require manual removal of the photovoltaic junction boxes and placement or hanging on specialized fixtures during automatic feeding. The boxes are then transported by conveyor belts and gripped by robots. There are no matching tooling fixtures suitable for photovoltaic junction boxes to be used together, resulting in high labor costs, low efficiency, and inaccurate placement and gripping, which is not conducive to subsequent processes.

[0006] Furthermore, during the welding process, the placement of photovoltaic junction boxes in photovoltaic modules is usually done manually. Since there is no installation location diagram on the appearance of photovoltaic modules for reference, two or more photovoltaic junction boxes in the same photovoltaic module often do not lie on a straight line or are not placed correctly during placement and fixing. Moreover, because the busbar is lightweight, it is easy for it to become skewed or partially extend beyond the edge under external force after placement. These situations / problems will cause the automatic welding machine to be unable to position the busbar correctly during the subsequent welding process, easily resulting in problems such as cold welds and insufficient welding area. Summary of the Invention

[0007] To address the problems existing in the prior art, this application provides a photovoltaic junction box lead processing and junction box installation welding method.

[0008] The technical solution to achieve the objective of this invention is: a photovoltaic junction box lead processing and junction box installation welding method, wherein the photovoltaic junction box lead processing and junction box installation welding method is implemented by a photovoltaic junction box lead processing and junction box installation welding integrated machine, the photovoltaic junction box lead processing and junction box installation welding integrated machine includes a lead processing backplate glue application integrated machine for straightening and glue application, a junction box installation integrated machine for installing junction boxes and busbars, and a junction box laser welding machine for welding, and the photovoltaic junction box lead processing and junction box installation welding method includes the following steps:

[0009] Step 1: The photovoltaic module is fed into the lead processing and backsheet glue application machine. The machine detects the angle of the busbar relative to the frame and the length of the busbar, and determines whether transparent tape or high-temperature tape was used during the lamination and sealing of the incoming module. The corresponding tape-removing mechanism is then used to remove the tape. The incoming module is then straightened and glued.

[0010] Step 2: The junction box to be installed is fed into the integrated junction box installation machine through the flow plate mechanism. Then, the robotic arm grabs the junction box from the flow plate mechanism. The reciprocating mechanism positions and transports the junction box. The junction box installation mechanism positions and shapes the busbars in the photovoltaic module after the glue has been applied, and then installs the busbars to the junction box.

[0011] Step 3: After installation, the photovoltaic modules enter the junction box laser welding machine. The junction box laser welding machine centers the photovoltaic modules. After centering, the machine takes the first photo and tightly attaches the photovoltaic module busbar to the copper base plate of the photovoltaic module junction box. Then, it takes the second photo. The junction box laser welding machine welds the busbar on the photovoltaic module junction box to the copper base plate in sequence according to the specified welding path.

[0012] As a preferred option, step one is as follows: the photovoltaic module is fed into the lead wire processing backsheet glue application machine via a conveyor belt. At this time, the calibration vision module positions the busbar on the photovoltaic module and determines whether transparent tape or high-temperature tape is used when the incoming module is laminated and sealed according to the preset program.

[0013] If it is high-temperature tape, the double-blade adhesive tearing mechanism will work. The double-blade body will descend to the back panel of the photovoltaic module. After bonding, the heating module will descend and bond above the high-temperature tape, melting the EVA adhesive under the high-temperature tape. Then, the double-blade body will scoop up the high-temperature tape from both sides. The clamping mechanism of the double-blade body will rise to clamp and pull the high-temperature tape upward. While the high-temperature tape is being pulled upward, the double-blade body will press the busbar into the guide groove of the pressing positioning block to position and straighten the busbar.

[0014] If it is transparent tape, the single-blade tearing mechanism will work, tearing the transparent tape directly from one end: the single blade body directly cuts into the root of the manifold and then straightens it;

[0015] For single-glass modules with transparent tape, an auxiliary bonding mechanism is required. This mechanism slightly lifts the backsheet busbars that are embedded in the lamination, and then straightens them. After the busbars are straightened, the multi-directional moving module transports the components on the main functional mounting frame forward along the Y-axis until the glue applicator's applicator head reaches above the busbars. At this point, the tape recycling mechanism, due to the contraction of the recycling cylinder, catches the components on the main functional mounting frame in the recycling trough. When the components reach below the double-blade or single-blade tearing mechanism, the clamping mechanism releases and drops the torn high-temperature tape or transparent tape into the recycling trough. The applicator head then applies glue evenly and stably according to the pre-set glue application path. After the glue application is completed, the photovoltaic module is sent out by the conveyor frame.

[0016] Preferably, step two is as follows: During the material loading process of the conveyor belt machine, when the lifting and positioning mechanism of the working position is in the lower designated position, the lifting conveyor belt is flush with the lower conveyor belt and the rear conveyor belt respectively. When the lifting and positioning mechanism of the working position is in the upper designated position, a single blister box can pass smoothly between the lifting conveyor belt and the lower conveyor belt. The lower conveyor belt can stack multiple blister boxes. When started, the dragging and clamping mechanism is outside the blister box. When the lifting mechanism lifts the first layer of blister boxes, it lifts all the stacked blister boxes. Then the dragging and clamping mechanism moves inward to support the bottom of the second layer of blister boxes. After that, the lifting mechanism descends until the first layer of blister boxes is placed on the lower conveyor belt. Then the first layer of blister boxes is conveyed to the lifting conveyor belt that is flush with the lower conveyor belt. After that, the lifting conveyor belt rises to the upper limit position, waiting for the robot arm to take the material from the blister box. After that, the lifting conveyor belt can directly convey the blister box to the rear conveyor belt.

[0017] After the robotic arm picks up the material from the blister pack, it uses a reciprocating mechanism to position and transport it to the designated workstation.

[0018] During junction box installation, the junction box mounting mechanism's junction box pick-and-place module clamps the junction box in the reciprocating mechanism → the busbar shaping module lowers to the middle of the busbar → the busbar shaping module positions and shapes the busbar → the junction box pick-and-place module aligns the junction box hole of the junction box with the busbar → the multi-directional installation and movement module slowly descends until the busbar passes through the junction box hole → the busbar shaping module retracts to avoid the junction box pick-and-place module → the junction box pick-and-place module presses down to the bottom, and after the junction box is installed in place, the junction box mounting mechanism moves backward, moves the busbar bending module above the junction box, and then lowers → the busbar bending module smooths the busbar parallel to the copper base plate of the junction box → the entire mechanism lifts to avoid the junction box.

[0019] As a preferred option, step three is as follows: the photovoltaic module enters the junction box laser welding machine → the module alignment mechanism centers the photovoltaic module. After the positioning is completed, the visual positioning mechanism moves to the top of the photovoltaic module junction box to take the first picture. After the first picture is taken, the visual positioning mechanism moves to the origin. The rotating pressing mechanism presses the junction box precisely according to the correction data to tightly fit the photovoltaic module busbar with the copper base plate of the photovoltaic module junction box.

[0020] The visual positioning mechanism moves back above the photovoltaic module junction box to take a second photo. After the second photo is taken, the visual positioning mechanism moves back to the original point, and the laser welding mechanism moves. The laser 113 sequentially welds the busbar on the photovoltaic module junction box to the copper base plate according to the specified welding path. After the welding is completed, the visual positioning mechanism moves above the photovoltaic junction box to perform welding appearance inspection on the welded photovoltaic module junction box.

[0021] This application also provides a photovoltaic junction box lead processing junction box installation and welding integrated machine using the aforementioned installation and welding method. The junction box installation integrated machine includes a flow plate mechanism for loading junction boxes, a robotic arm mechanism for gripping junction boxes on the flow plate mechanism, a reciprocating mechanism for positioning and conveying junction boxes, a positioning vision mechanism for positioning the position of busbars on photovoltaic modules, and a junction box installation mechanism for installing the junction boxes and busbars.

[0022] The assembly mechanism includes an assembly machine frame and a lower conveyor belt, a lifting conveyor belt, and a rear conveyor belt arranged sequentially within the assembly machine frame. The lifting conveyor belt is equipped with a working position lifting and positioning mechanism, and the lower conveyor belt is equipped with a blister box for positioning the junction box body, junction box plug, and junction box wire.

[0023] The blister box includes a blister box body and at least one photovoltaic junction box placement cavity mechanism disposed on the blister box body. Each of the photovoltaic junction box placement cavity mechanisms includes a junction box body placement cavity, a junction box plug placement cavity, and a junction box wire placement cavity.

[0024] Preferably, the integrated lead wire processing and backsheet adhesive application machine includes a conveyor frame, a multi-directional moving module, a correction vision module, a main functional mounting frame, and an adhesive application energy storage device. The conveyor frame is used to transport photovoltaic modules, and a tape recycling mechanism is provided on one side of the conveyor frame. The correction vision module and the multi-directional moving module are respectively provided on the conveyor frame. The correction vision module is used to position the busbars on the photovoltaic modules. The multi-directional moving module can drive the main functional mounting frame to move along the X-axis and Y-axis. The main functional mounting frame is respectively provided with a movable double-blade adhesive tearing mechanism, a single-blade adhesive tearing mechanism, a vision inspection module, a heating module, an auxiliary bonding module, and an adhesive application mechanism. The movements of the double-blade adhesive tearing mechanism, the single-blade adhesive tearing mechanism, the vision inspection module, the heating module, the auxiliary bonding module, and the adhesive application mechanism do not interfere with each other. An adhesive application energy storage device is provided above the main functional mounting frame.

[0025] Preferably, the dual-blade adhesive-tearing mechanism includes a straightening and tearing mounting plate, a moving adjustment mechanism, a clamping mechanism, an elastic pressing component, and a dual-blade assembly. A Z-axis lifting module is provided on one side of the main functional mounting frame. The straightening and tearing mounting plate is fixedly mounted at the lower end of the Z-axis lifting module. A moving adjustment mechanism is fixedly mounted on the straightening and tearing mounting plate. A clamping mechanism is provided below the moving adjustment mechanism. An elastic pressing component is provided at the lower end of the clamping mechanism. Dual-blade assemblies are symmetrically arranged on both sides of the elastic pressing component. The dual-blade assembly includes a dual-blade fixing block, a dual-blade adjusting block, and a dual-blade rotating block. The device comprises a shaft, a double-blade body, and a double-blade spring. The movable adjustment mechanism is fixedly connected to the upper end of the double-blade fixing block on its side. The double-blade fixing block is L-shaped, and an adjustment screw passes through the lower part of the double-blade fixing block. One end of the adjustment screw is connected to the double-blade adjustment block, and the bottom of the double-blade adjustment block is fixed to the inner side of the double-blade fixing block. Double-blade rotating shafts pass through the inside of both sides of the double-blade adjustment block. The double-blade body is movably connected to the double-blade rotating shaft, and the double-blade spring abuts against the double-blade body. The other end of the double-blade spring abuts against the double-blade adjustment block.

[0026] Preferably, the single-blade adhesive-tearing mechanism includes an adhesive-tearing mounting top plate, a Z-axis slide cylinder, a Y-axis slide cylinder, a single-blade fixing block, a single-blade adjusting block, and a single-blade body. An adhesive-tearing mounting base plate is provided on the outer side of the Z-axis lifting module. The front side of the adhesive-tearing mounting base plate is connected to the adhesive-tearing mounting top plate. A Z-axis slide cylinder is fixedly mounted on the upper end of the adhesive-tearing mounting top plate for movement in the Z-axis direction. A Y-axis slide cylinder is fixedly mounted on one side of the lower end of the adhesive-tearing mounting top plate. The output end of the Y-axis slide cylinder is adapted and connected to the upper end of the single-blade fixing block. A single-blade adjusting block is fixedly mounted on the lower end of the single-blade fixing block. An installation groove is provided inside the adjusting block, and a single shovel body is rotatably installed in the installation groove. One end of the single shovel body is adapted to the output end of a small cylinder through a top column. The small cylinder is fixed to the inner side of the upper surface of the single shovel adjusting block. A second air pipe connector is provided on the outer side of the single shovel adjusting block. The lower end of the second air pipe connector is connected to the installation groove. A single shovel rotating shaft is provided in the installation groove. The single shovel rotating shaft passes through the single shovel body and is rotatably connected to it. A clamping block is provided at one end of the bottom of the single shovel adjusting block. The lower end of the clamping block can contact and connect with the other end of the single shovel body.

[0027] Preferably, the junction box laser welding machine includes a frame, a conveying mechanism, a straightening mechanism, a lifting mechanism, a laser welding mechanism, a rotating pressing mechanism, and a visual positioning mechanism. The frame is equipped with a conveying mechanism, and straightening mechanisms are provided on both sides of the conveying mechanism, while a lifting mechanism is slidably provided at the bottom. The laser welding mechanism and the rotating pressing mechanism are slidably arranged on the upper end of the frame, and a visual positioning mechanism is arranged parallel to the laser welding mechanism below it, with the bottom of the visual positioning mechanism being higher than the bottom of the rotating pressing mechanism.

[0028] Preferably, the laser welding mechanism includes a laser X-axis module, a fixed top plate, a laser head side plate, a laser head mounting plate, a laser Z-axis module, and a laser. The laser X-axis module is fixedly mounted on the upper end of the frame, and the fixed top plate is slidably connected to the laser X-axis module. Laser head side plates are fixed on both sides of the fixed top plate. The lower ends of the laser head side plates are bent forward and extend parallel to the fixed top plate. One end of the laser head side plate and one end of the fixed top plate are both fixedly connected to the back side of the laser head mounting plate. The laser Z-axis module is fixedly mounted on the front side of the laser head mounting plate, and a laser is slidably connected to the laser Z-axis module.

[0029] By adopting the above technical solution, the present invention has the following beneficial effects: (1) The present invention integrates photovoltaic junction box for lead wire processing, installation and welding, with a high degree of automation and high precision.

[0030] The junction box installation integrated machine in this application can realize the transportation and installation of junction boxes and the positioning of busbars, improve the accuracy of process actions, and match the unique tooling fixture blister box with each conveyor belt of the photovoltaic junction box conveyor production line. This makes it convenient for the robotic arm mechanism to clamp and load materials during automatic feeding of the photovoltaic junction box conveyor equipment. The machine is efficient and the clamping and placement are precise, eliminating the need for manual removal of photovoltaic junction boxes and placement or hanging on special fixtures.

[0031] This invention relates to an integrated lead wire processing and backsheet adhesive application machine. A conveyor frame is used to transport photovoltaic modules, and a tape recycling mechanism is located on one side of the conveyor frame. The conveyor frame is equipped with a correction vision module and a multi-directional movement module. The correction vision module is used to position the busbars on the photovoltaic modules. The multi-directional movement module can move the main functional mounting frame along the X and Y axes. The main functional mounting frame is equipped with movable, non-interfering double-blade adhesive tearing mechanism, a single-blade adhesive tearing mechanism, a vision inspection module, a heating module, an auxiliary bonding module, and an adhesive application mechanism. An adhesive application energy storage device is located above the main functional mounting frame. This machine can automatically complete the tearing of high-temperature tape, busbar straightening, and adhesive application on a single machine, saving equipment and labor costs and improving production efficiency and stability.

[0032] The invention features a double-blade tearing mechanism that can automatically remove high-temperature tape, improving production efficiency and saving labor costs. It can also adjust the tearing angle and width according to the size of different high-temperature tapes, ensuring complete removal of the high-temperature tape from the busbar without damaging it.

[0033] The junction box laser welding machine of this invention features a conveying mechanism within the frame, with alignment mechanisms on both sides and a lifting mechanism sliding at the bottom. A laser welding mechanism and a rotating pressing mechanism are slidably mounted on the upper part of the frame. A visual positioning mechanism is parallel to the laser welding mechanism, with its bottom higher than the bottom of the rotating pressing mechanism. This ensures that the movements of the laser welding mechanism, rotating pressing mechanism, and visual positioning mechanism do not interfere with each other, resulting in a compact overall layout. Only one visual camera component is needed to complete the photographing and positioning of photovoltaic modules, welding positioning, and post-weld appearance inspection. Because the laser, visual camera component, and pressing head can be on the same vertical line during movement, when the visual camera component retracts after the first photographing and positioning of the photovoltaic module, the retraction path will not touch other components, causing any deviation in the photographed position. This results in more accurate positioning. Subsequent pressing and welding of the photovoltaic module by the laser welding mechanism or rotating pressing mechanism can also be performed automatically and quickly, resulting in a high pass rate, improved overall equipment production efficiency, and reduced material costs. Furthermore, secondary photographing enhances welding stability. Attached Figure Description

[0034] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings, wherein...

[0035] Figure 1 A top view of the photovoltaic junction box lead processing and junction box installation welding integrated machine of the present invention;

[0036] Figure 2 This is a schematic diagram of the overall structure of the present invention;

[0037] Figure 3 This is an exploded view of the overall structure of the present invention;

[0038] Figure 4 This is one of the internal structural diagrams of the present invention;

[0039] Figure 5 This is a second schematic diagram of the internal structure of the present invention;

[0040] Figure 6 This is a schematic diagram of the main functional mounting bracket of the present invention;

[0041] Figure 7 For the present invention Figure 6 Partial exploded view;

[0042] Figure 8 This is one of the structural schematic diagrams of the double-blade adhesive-tearing mechanism of the present invention;

[0043] Figure 9 This is a second schematic diagram of the structure of the double-blade adhesive-tearing mechanism of the present invention;

[0044] Figure 10 This is an exploded view of the double-blade adhesive-tearing mechanism of the present invention;

[0045] Figure 11 This is a front view of the double-blade adhesive-tearing mechanism of the present invention;

[0046] Figure 12 This is a cross-sectional view of the double-blade adhesive-tearing mechanism of the present invention;

[0047] Figure 13 For the present invention Figure 11 Enlarged view of point A;

[0048] Figure 14 This is a schematic diagram of the single-blade adhesive-tearing mechanism of the present invention;

[0049] Figure 15 This is a cross-sectional view of the single-blade adhesive-tearing mechanism of the present invention;

[0050] Figure 16 For the present invention Figure 14 Enlarged view of point A;

[0051] Figure 17 This is a top view of the junction box mounting unit of the present invention;

[0052] Figure 18 For the present invention Figure 17 Schematic diagram of the flow plate mechanism;

[0053] Figure 19 For the present invention Figure 18 Schematic diagram of the structure of the blister pack;

[0054] Figure 20 In this invention Figure 17 A partial structural schematic diagram (the flow disk mechanism is not shown);

[0055] Figure 21 for Figure 20 A schematic diagram of the decomposition process;

[0056] Figure 22 for Figure 21 Enlarged schematic diagram of the reciprocating mechanism;

[0057] Figure 23 This is a front view of the junction box laser welding machine of the present invention;

[0058] Figure 24 This is an exploded view of the overall structure of the junction box laser welding machine of the present invention;

[0059] Figure 25 This is a side view of the laser welding mechanism of the present invention;

[0060] Figure 26 This is a schematic diagram of the overall structure of the rotary pressing mechanism of the present invention;

[0061] Figure 27 This is a partial structural schematic diagram of the rotary pressing mechanism of the present invention;

[0062] Figure 28 For the present invention Figure 27 Exploded view;

[0063] Figure 29 This is a schematic diagram of the visual positioning mechanism of the present invention. Detailed Implementation

[0064] Example 1

[0065] The following will combine Figure 1-29 The present invention will be described in detail below. The illustrative embodiments and descriptions herein are used to explain the invention, but are not intended to limit the invention.

[0066] A photovoltaic junction box lead processing, junction box installation, and welding integrated machine includes a lead processing and backplate glue application integrated machine for straightening and applying glue, a junction box installation integrated machine for installing junction boxes and busbars, and a junction box laser welding machine for welding.

[0067] like Figures 1 to 16 As shown, a lead wire processing backplane glue application integrated machine includes a conveyor frame 401, a multi-directional moving module 402, a correction vision module 403, a main function mounting frame 404, a glue application energy storage device 405, a double-blade glue-tearing mechanism 406, a single-blade glue-tearing mechanism 407, a vision inspection module 408, a heating module 409, an auxiliary bonding module 410, a glue application mechanism 411, a Z-axis lifting module 412, a glue-tearing mounting base plate 413, and a glue application moving module 404. 14. Recycling tank 415. Recycling cylinder 416. Straightening and tearing adhesive mounting plate 201. Moving adjustment mechanism 202. Clamping mechanism 203. Elastic pressing assembly 204. Double shovel assembly 205. Double shovel fixing block 206. Double shovel adjusting block 207. Double shovel rotating shaft 208. Double shovel body 209. Double shovel spring 210. Adjusting screw 211. Fixing block one 212. Pneumatic finger 213. Guide rail plate 214. Linear guide rail one 215. Clamping slider plate 216, guide mounting block 217, bearing one 218, pressing connecting block 219, fixing block two 220, bearing two 221, telescopic rod 222, limiting block 223, pressing positioning plate 224, compression spring 225, pressing positioning block 226, vent hole 227, first air pipe connector 228, adjusting cylinder 229, moving connecting block 230, linear guide rail two 231, moving adjusting block 232, floating joint 233, screw 2 34. Screw fixing block 235. Buffer pad 236. Blocking plate 237. Guide component 238. Waist hole 239. Clamping block 240. Adhesive-removable mounting top plate 301. Z-axis slide cylinder 302. Y-axis slide cylinder 303. Single shovel fixing block 304. Single shovel adjusting block 305. Single shovel body 306. Small cylinder 307. Second air pipe connector 308. Clamping block 309. Buffer spring 310. Single shovel rotating shaft 311 and top column 312.

[0068] like Figures 1 to 15 As shown, the conveyor frame 401 is used to transport photovoltaic modules. A tape recycling mechanism is provided on one side of the conveyor frame 401. The tape recycling mechanism includes a recycling trough 415 and a recycling cylinder 416. Recycling cylinders 416 are installed at both ends of the recycling trough 415. The output end of the recycling cylinder 416 is adapted to the multi-directional moving module 402.

[0069] The conveyor frame 401 is equipped with a correction vision module 403 and a multi-directional movement module 402. The correction vision module 403 is used to position the busbars on the photovoltaic modules. The multi-directional movement module 402 can drive the main functional mounting frame 404 to move along the X-axis and Y-axis. The main functional mounting frame 404 is equipped with a movable double-blade adhesive tearing mechanism 406, a single-blade adhesive tearing mechanism 407, a vision inspection module 408, a heating module 409, an auxiliary bonding module 410, and a glue application mechanism 411. The movements of the double-blade adhesive tearing mechanism 406, the single-blade adhesive tearing mechanism 407, the vision inspection module 408, the heating module 409, the auxiliary bonding module 410, and the glue application mechanism 411 do not interfere with each other.

[0070] Specifically, a vision inspection module 408 is provided at the lower middle part of the main function mounting bracket 404. The vision inspection module 408 can move along the Z-axis direction of the main function mounting bracket 404 to detect the angle of the busbar relative to the frame and the length of the busbar.

[0071] A glue dispensing energy storage device 405 is provided above the main functional mounting bracket 404, and a glue dispensing mechanism 411 is provided on the other side of the main functional mounting bracket 404. The glue dispensing mechanism 411 is adapted to the glue dispensing energy storage device 405 through a pipe. The glue dispensing mechanism 411 can move along the X-axis and Y-axis of the main functional mounting bracket 404 through the glue dispensing moving module 414 to complete the glue dispensing path.

[0072] The double-blade adhesive-tearing mechanism 406 includes a straightening and tearing mounting plate 201, a moving adjustment mechanism 202, a clamping mechanism 203, an elastic pressing component 204, and a double-blade assembly 205. A Z-axis lifting module 412 is provided on one side of the main functional mounting frame 404. The straightening and tearing mounting plate 201 is fixedly mounted at the lower end of the Z-axis lifting module 412. Blocking plates 237 are provided on both sides of the straightening and tearing mounting plate 201. The moving adjustment mechanism 202 is fixedly mounted on the straightening and tearing mounting plate 201. Specifically, the moving adjustment mechanism 202 includes an adjusting cylinder 229, a moving connecting block 230, a linear guide rail 231, and a moving adjustment block. 232. Adjusting cylinders 229 are fixedly installed on both sides of the straightening and tearing adhesive mounting plate 201 to control the opening and clamping of the double shovel assembly 205. The output end of the adjusting cylinder 229 is connected to the movable connecting block 230 through the floating joint 233. One side of the movable connecting block 230 is slidably connected to the linear guide rail 231. Movable adjusting blocks 232 are provided on both sides of the linear guide rail 231. The movable connecting block 230 is adjustablely connected to the upper end of the double shovel fixing block 206 through the adjusting screw 234. In this embodiment, the adjusting screw 234 is an internal hexagonal adjusting screw that can be used to adjust the clamping width of the double shovel assembly 205.

[0073] Below the movable adjustment mechanism 202 is a clamping mechanism 203. Specifically, the clamping mechanism 203 includes a fixing block 212, a pneumatic finger 213, a guide rail plate 214, a linear guide rail 215, a clamping slider plate 216, a guide mounting block 217, and a bearing 218. The fixing block 212 is installed in the center below the straightening adhesive-removing mounting plate 201. The pneumatic finger 213 is located directly below the fixing block 212. The guide rail plate 214 is slidably connected to both sides of the pneumatic finger 213. The linear guide rail 215 is vertically installed on the inner side of the guide rail plate 214. The clamping slider plate 216 is slidably connected to the linear guide rail 215. The clamping slider plate 216 has a clamping block 240 inside for clamping high-temperature tape. The clamping slider plate 216 has a guide mounting block 217, and the bearing 218 is fixedly installed on the guide mounting block 217.

[0074] The clamping mechanism 203 is provided with an elastic pressing component 204 at its lower end. Specifically, the elastic pressing component 204 includes a pressing connecting block 219, a second fixing block 220, a second bearing 221, a telescopic rod 222, a limiting block 223, a pressing positioning plate 224, a compression spring 225, a pressing positioning block 226, a vent hole 227, and a first air pipe connector 228. The pneumatic finger 213 is provided with pressing connecting blocks 219 at its front and rear ends respectively. The second fixing block 220 is fixedly provided at the lower part of the pressing connecting block 219. The second fixing block 220 is symmetrically provided with guide members 238. The guide members 238 are provided with waist holes 239. The first bearing 218 is movably provided in the waist holes 239.

[0075] The second fixed block 220 has bearings 221 symmetrically arranged on both sides. A telescopic rod 222 is adapted to be installed in the bearing 221. A limiting block 223 is provided at the top of the telescopic rod 222. A buffer pad 236 is provided between the telescopic rod 222 and the limiting block 223. A pressing positioning plate 224 is provided at the lower part of the telescopic rod 222. A compression spring 225 is sandwiched between the upper end of the pressing positioning plate 224 and the lower end of the second fixed block 220. A pressing positioning block 226 is provided directly below the pressing positioning plate 224. A vent hole 227 is provided on the front side of the pressing positioning block 226. The vent hole 227 is connected to the first air pipe connector 228.

[0076] The elastic pressing component 204 has symmetrically arranged double-blade components 205 on both sides. The double-blade components 205 include a double-blade fixing block 206, a double-blade adjusting block 207, a double-blade rotating shaft 208, a double-blade body 209, and a double-blade spring 210. The side of the moving adjustment mechanism 202 is fixedly connected to the upper end of the double-blade fixing block 206. The double-blade fixing block 206 has an "O" shaped groove to reduce the weight of the double-blade components 205 and facilitate their movement. The double-blade fixing block 206 is "L" shaped, and an adjusting screw 211 passes through the lower part of the double-blade fixing block 206. A screw fixing block 235 is fixedly installed on the outer side of the double-blade fixing block 206, and the screw fixing block 235 is adapted to and connected to the adjusting screw 211.

[0077] One end of the adjusting screw 211 is connected to the double scraper adjusting block 207. The bottom of the double scraper adjusting block 207 is fixed to the inside of the double scraper fixing block 206. Double scraper rotating shafts 208 are inserted through both sides of the double scraper adjusting block 207. The double scraper body 209 is movably connected to the double scraper rotating shaft 208. The double scraper body 209 is abutted against the double scraper spring 210. The other end of the double scraper spring 210 abuts against the double scraper adjusting block 207, so that the double scraper adjusting block 207 and the double scraper body 209 form an elastic mechanism. The lower end of the double scraper body 209 is relatively inclined inward and downward. When scraping up the high-temperature tape, a relatively gentle lateral force is used, which will not directly damage the busbar.

[0078] The double shovel adjustment block 207 fixes the double shovel body 209 to the side via the double shovel pivot 208, and a compression spring is installed between the shovel adjustment block and the shovel to form an elastic mechanism.

[0079] The working principle of the double-blade adhesive tearing mechanism 406 is as follows: The pressing positioning block 226 is pressed into the center position of the two manifolds by the compression spring 225, the adjusting cylinder 229 clamps, the clamping mechanism 203 rises, and the double-blade body 209 presses the manifolds into the guide groove of the pressing positioning block 226 to position and straighten the manifolds (the number of straightening actions is set according to the on-site work requirements). The pneumatic finger 213 clamps and runs horizontally. The bearing 218 guides and slides within the range of the waist hole 239, and the vertically installed linear guide rail 215 slides vertically to complete the up and down movement and clamping action, so as to cooperate with the clamping block 240 to clamp the high-temperature tape pulled up by the double-blade body 209.

[0080] When the high-temperature tape is recycled, the pneumatic finger 213 clamps and moves horizontally, the bearing 208 slides in the waist hole 239 and slides vertically with the vertically installed linear guide rail 215 to complete the up and down movement and opening action, and the vent hole 227 on the front side of the pressing positioning block 226 completes the recycling of the high-temperature tape by compressed air blowing through the first air pipe joint 228.

[0081] The 406 dual-blade adhesive tearing mechanism can automatically tear off high-temperature tape, improving production efficiency and saving labor costs. It can also adjust the tearing angle and width according to the size of different high-temperature tapes to ensure complete removal of high-temperature tape from the busbar without damaging the busbar.

[0082] The single-blade adhesive-tearing mechanism 407 includes an adhesive-tearing mounting top plate 301, a Z-axis slide cylinder 302, a Y-axis slide cylinder 303, a single-blade fixing block 304, a single-blade adjusting block 305, and a single-blade body 306. An adhesive-tearing mounting base plate 413 is provided on the outer side of the Z-axis lifting module 412. The front side of the adhesive-tearing mounting base plate 413 is connected to the adhesive-tearing mounting top plate 301. The upper end of the adhesive-tearing mounting top plate 301 is fixed with the Z-axis slide cylinder 302 for movement in the Z-axis direction. A Y-axis slide cylinder is fixed on one side of the lower end of the adhesive-tearing mounting top plate 301. The output end of the Y-axis slide cylinder 303 is adapted and connected to the upper end of the single shovel fixing block 304. A gap is left between the upper end of the single shovel fixing block 304 and the adhesive removal mounting plate 301. A single shovel adjusting block 305 is fixed at the lower end of the single shovel fixing block 304. The single shovel adjusting block 305 is arranged parallel to the Y-axis slide cylinder 303. The Z-axis slide cylinder 302 and the Y-axis slide cylinder 303 can work together to drive the single shovel fixing block 304 and the single shovel body 306 to lift and lower, thus removing the transparent tape.

[0083] The single blade adjusting block 305 has a mounting groove, in which the single blade body 306 is rotatably mounted. Specifically, the mounting groove contains a single blade rotating shaft 311, which passes through and is rotatably connected to the single blade body 306. One end of the single blade body 306 is adapted to the output end of a small cylinder 307 via a top post 312. The small cylinder 307 is fixed to the inner side of the upper surface of the single blade adjusting block 305. A second air pipe connector 308 is provided on the outer side of the single blade adjusting block 305, and the lower end of the second air pipe connector 308 communicates with the mounting groove.

[0084] The single-blade adjusting block 305 has a clamping block 309 at one bottom end, and the lower end of the clamping block 309 can contact and connect with the other end of the single-blade body 306. Specifically, the included angle on both sides of the lower end of the clamping block 309 is an obtuse angle, and the bottom of the clamping block 309 can move to fit against the single-blade body 306. The single-blade body 306 and the clamping block 309 work together to completely remove transparent tape.

[0085] A placement groove is provided on the single scraper body 306, and one end of a buffer spring 310 is placed in the placement groove. The other end of the buffer spring 310 is placed on the single scraper adjusting block 305. This provides an elastic buffer force to the single scraper body 306, allowing the scraping part of the single scraper body 306 to make flexible contact with the photovoltaic panel busbar without directly damaging it.

[0086] The working principle of the single-blade adhesive tearing mechanism 407 is as follows: the Z-axis slide cylinder 302 and the Y-axis slide cylinder 303 extend in cooperation, and the single blade body 306 contacts the transparent tape on the manifold. At this time, the small cylinder 307 extends and presses down one end of the single blade body 306. Under the action of the single blade rotating shaft 311, the other end of the single blade body 306 is lifted to clamp the transparent tape.

[0087] The Z-axis slide cylinder 302 and the Y-axis slide cylinder 303 work together to retract simultaneously, thus removing the transparent tape. The second air pipe connector 308 then vents to complete the recycling of the transparent tape.

[0088] The single-blade adhesive-tearing mechanism 407 can adapt to tearing transparent tape of different specifications on photovoltaic panel busbars. While tearing off the transparent tape, it connects to the second air pipe connector to complete the recycling of the transparent tape. The transparent tape can be torn off cleanly without manual intervention.

[0089] Both the double-blade fixing block 206 and the single-blade fixing block 304 are provided with "O" shaped grooves, which reduce the weight of the entire device and facilitate the movement of the double-blade adhesive tearing mechanism 406 and the single-blade adhesive tearing mechanism 407.

[0090] An auxiliary bonding module 410 is provided on the rear side of the adhesive-removable mounting base plate 413. The auxiliary bonding module 410 can move up and down along the setting direction of the adhesive-removable mounting base plate 413 to bond the busbar.

[0091] like Figures 17 to 22 As shown, the junction box installation machine of this embodiment includes a feeder mechanism 5 for loading junction boxes, a robotic arm mechanism 7 for gripping junction boxes 12 on the feeder mechanism, a reciprocating mechanism 8 for positioning and conveying junction boxes, a positioning vision mechanism 10 for positioning the position of busbars on photovoltaic modules, and a junction box installation mechanism 9 for installing the junction boxes and busbars.

[0092] The junction box installation mechanism includes a multi-directional installation and movement module, a moving busbar shaping module, a junction box pick-and-place module, and a busbar bending module. The junction box pick-and-place module is used to grab the junction box from the reciprocating mechanism. The busbar shaping module is used to shape the busbar at a specified angle. The junction box hole of the junction box passes through the busbar and is installed on the photovoltaic module. The busbar bending module is used to bend the installed busbar to fit against the welding plane of the junction box. The junction box installation mechanism also includes a re-inspection vision module, which is used to capture images to determine whether the installation status of the busbar and junction box is qualified. The robotic arm mechanism, reciprocating mechanism, positioning vision mechanism, and junction box mounting mechanism are all connected to the mounting frame. The flow plate mechanism is fixed on the lower platform of the mounting frame. The reciprocating mechanism is fixed to the rear end of the middle platform of the mounting frame via guide rail sliders. The robotic arm mechanism is fixed to the rear end of the middle platform of the mounting frame, directly above the reciprocating mechanism. The positioning vision mechanism is fixed on the flow plate mechanism. The junction box mounting mechanism is fixed to the upper platform of the mounting frame via guide rail sliders. The outer cover is fixed to the middle platform of the mounting frame.

[0093] The reciprocating mechanism positions and transports the junction box. The positioning is achieved by three sets of reciprocating positioning mechanisms on the reciprocating mechanism, which position the junction box at three different locations. Each set of reciprocating positioning mechanisms consists of one reciprocating positioning block and three reciprocating cylinders. The transport is accomplished by a reciprocating motor driving a synchronous pulley belt assembly.

[0094] The assembly mechanism includes an assembly machine frame and a lower conveyor belt 501, a lifting conveyor belt 502, and a rear conveyor belt 503 arranged sequentially within the assembly machine frame. The lifting conveyor belt is equipped with a working position lifting and positioning mechanism 509, which is preferably a cylinder. The lower conveyor belt is equipped with a blister box 6 for positioning the junction box body, junction box plug, and junction box wire.

[0095] The blister box includes a blister box body 61 and at least one photovoltaic junction box placement cavity mechanism disposed on the blister box body. Each photovoltaic junction box placement cavity mechanism includes a junction box body placement cavity 62, a junction box plug placement cavity 63, and a junction box wire placement cavity 64. The blister box body is provided with a clamping clearance 65 and several inverted buckles 66 for supporting the stacking space.

[0096] The photovoltaic junction box feeding conveyor also includes a blocking positioning mechanism for blocking the conveying of blister boxes, the blocking positioning mechanism being a rotary blocking positioning mechanism 504.

[0097] This application is suitable not only for single junction boxes, but especially for three-part photovoltaic junction boxes. The photovoltaic junction box is a three-part photovoltaic junction box, which includes a positive junction box, a negative junction box, and an intermediate junction box. Each of the photovoltaic junction box placement cavity mechanisms is used to place the positive junction box, the negative junction box, and the intermediate junction box. A junction box body placement cavity, a junction box plug placement cavity, and a junction box wire placement cavity constitute a positive junction box placement cavity 67. A junction box body placement cavity, a junction box plug placement cavity, and a junction box wire placement cavity constitute a negative junction box placement cavity 68. The positive junction box placement cavity and the negative junction box placement cavity are arranged opposite to each other. The intermediate junction box placement cavity 69 is located between the positive junction box placement cavity and the negative junction box placement cavity.

[0098] like Figures 23 to 29As shown, a junction box laser welding machine includes a frame 101, a conveying mechanism 102, a straightening mechanism 103, a lifting mechanism 104, a laser welding mechanism 105, a rotating pressing mechanism 106, a vision positioning mechanism 107, a laser X-axis module 108, a fixed top plate 109, a laser head side plate 110, a laser head mounting plate 111, a laser Z-axis module 112, a laser 113, a vision linear module 114, a vision electric cylinder 115, a vision base plate 116, a vision adjustment assembly 117, a vision adjustment block 118, a vision camera assembly 119, a pressing Y-axis module 120, a movable pressing fixing plate 121, a pressing X-axis assembly 122, a rotating fixing plate 123, a rotating assembly 124, a rotating seat 125, an elastic pressing mechanism 126, a pressing lifting cylinder 127, a pressing cantilever 128, a pressing head 129, a clearance groove 130, and a lighting assembly 131. The overall layout of this invention is compact. Only one vision camera component 119 is needed to complete the photo positioning, welding positioning, and post-weld appearance inspection of photovoltaic modules. Since the laser 113, vision camera component 119, and pressing head 129 can be on the same vertical line during movement, when the vision camera component 119 retreats after the first photo positioning of the photovoltaic module, the retreat path will not touch other components, causing the position determined by the photo to be offset. The positioning is more accurate. The subsequent pressing and welding of the photovoltaic module by the laser welding mechanism 105 or the rotating pressing mechanism 106 can also be carried out in a timely and fast manner, with a high pass rate. This improves the overall production efficiency of the equipment, saves material costs, and also improves the stability of welding.

[0099] The frame 101 is equipped with a conveying mechanism 102. The conveying mechanism 102 is equipped with a straightening mechanism 103 on both sides and a lifting mechanism 104 sliding at the bottom. The upper end of the frame 101 is equipped with a laser welding mechanism 105 and a rotary pressing mechanism 106 that slide relative to each other. A visual positioning mechanism 107 is provided parallel below the laser welding mechanism 105. The visual positioning mechanism 107 and the rotary pressing mechanism 106 are at least one set. The bottom of the visual positioning mechanism 107 is higher than the bottom of the rotary pressing mechanism 106. Specifically, the bottom of the visual camera assembly 119 is higher than the top of the pressing head 129, so that the movement of the laser welding mechanism 105, the rotary pressing mechanism 106 and the visual positioning mechanism 107 does not interfere with each other.

[0100] The rotary pressing mechanism 106 includes a Y-axis pressing module 120, a movable pressing fixed plate 121, an X-axis pressing component 122, a rotary fixed plate 123, a rotary component 124, a rotary seat 125, an elastic pressing mechanism 126, a pressing lifting cylinder 127, a pressing cantilever 128, and a pressing head 129. The Y-axis pressing module 120 is slidably connected to the frame 101. One end of the Y-axis pressing module 120 is provided with a movable pressing fixed plate 121. The X-axis pressing component 122 is fixedly mounted on the inner side of the movable pressing fixed plate 121. The output end of the X-axis pressing component 122 drives... The rotating fixed plate 123 moves up and down along the movable pressing fixed plate 121. The rotating fixed plate 123 is provided with a rotating component 124. The output end of the rotating component 124 is connected to the rotating seat 125. The rotating seat 125 is rotatably connected to the rotating fixed plate 123. An elastic pressing mechanism 126 is fixed on the outer side of the rotating seat 125. A pressing lifting cylinder 127 is slidably connected to the inner side of the rotating seat 125. The output end of the pressing lifting cylinder 127 is adapted to the pressing cantilever 128. The lower part of the pressing cantilever 128 bends forward and extends and is fixedly connected to the pressing head 129.

[0101] The elastic pressing mechanism 126 has an inner clearance groove 130, into which the pressing head 129 extends and moves. The rotating component 124 further improves the positional accuracy between the pressing head 129 and the junction box, providing a basis for accurately fixing the junction box in the future. The elastic pressing mechanism 126 fixes the junction box by pressing the X-axis component 122, providing a basis for accurately attaching the busbar and conductive terminals in the future. The pressing head 129 presses the lifting cylinder 127 to press and attach the busbar and conductive terminals, ensuring a good welding effect when laser welding is performed in the future.

[0102] Specifically, the working principle of the rotating pressing mechanism 106 is as follows: the photovoltaic module is transported to the bottom of the pressing head 129 for initial positioning, the vision camera component 119 takes a picture to obtain the position of the junction box, and the rotating component 124 drives the rotating seat 125 to rotate according to the position of the junction box, so that the pressing head 129 is aligned with the junction box, and the precise positioning of the junction box is completed.

[0103] The X-axis component 122 drives the rotating fixed plate 123 to descend, thereby causing the elastic pressing mechanism 126 to descend. The elastic pressing mechanism 126 fixes the junction box by pressing. Then, the pressing head 129 moves downward into the junction box under the drive of the pressing lifting cylinder 127 to complete the pressing and bonding steps of the bus bar and conductive terminals, providing a guarantee for the subsequent operation of the laser welding mechanism 105.

[0104] The laser welding mechanism 105 includes a laser X-axis module 108, a fixed top plate 109, a laser head side plate 110, a laser head mounting plate 111, a laser Z-axis module 112, and a laser 113. The laser X-axis module 108 is fixedly installed on the upper end of the frame 101. The fixed top plate 109 is slidably connected to the laser X-axis module 108. The laser head side plates 110 are fixed on both sides of the fixed top plate 109. The lower end of the laser head side plate 110 bends forward and extends parallel to the fixed top plate 109. One end of the laser head side plate 110 and one end of the fixed top plate 109 are fixedly connected to the back side of the laser head mounting plate 111. The laser Z-axis module 112 is fixedly installed on the front side of the laser head mounting plate 111. The laser 113 is slidably connected to the laser Z-axis module 112.

[0105] Specifically, the laser welding mechanism 105 moves according to the image capture position of the vision camera assembly 119. After moving above the busbar, the laser Z-axis module 112 drives the laser 113 to descend and perform laser welding on the busbar.

[0106] The visual positioning mechanism 107 includes a visual linear module 114, a visual electric cylinder 115, a visual base plate 116, a visual adjustment component 117, a visual adjustment block 118, and a visual camera component 119. The visual linear module 114, which is parallel to the laser X-axis module 108, is mounted on the frame 101. The visual electric cylinder 115 is spaced apart on one side of the visual linear module 114. The output end of the visual electric cylinder 115 is adapted and connected to the visual base plate 116. The two ends of the visual base plate 116 are slidably connected to the visual linear module 114. The visual adjustment component 117 is mounted on the visual base plate 116. The visual adjustment component 117 is adapted and connected to the visual camera component 119 through the visual adjustment block 118. The visual camera component 119 moves up and down and left and right on the visual base plate 116 through the movement of the visual adjustment component 117.

[0107] Specifically, the working principle of the visual positioning mechanism 107 is as follows: when the position of the visual camera component 119 needs to be readjusted, its position on the visual base plate 116 is adjusted by the visual adjustment component 117. When the position of the visual camera component 119 is adjusted in the front, back, left and right, the lighting component 131 will be adjusted synchronously to ensure that the light source of the visual camera component 119 will not shift when taking pictures.

[0108] When the vision camera assembly 119 is positioned at the height of the vision base plate 116, it is not necessary to move the lighting assembly 131 and the vision adjustment assembly 117. This configuration reduces the difficulty of moving the vision camera assembly 119 up and down, and allows for more flexible adjustment of the height position of the vision camera assembly 119.

[0109] The laser 113, the vision camera assembly 119, and the pressing head 129 can be on the same vertical line during movement.

[0110] This application discloses a photovoltaic junction box lead processing and junction box installation welding method, which is implemented using the integrated photovoltaic junction box lead processing and junction box installation welding machine. The photovoltaic junction box lead processing and junction box installation welding method includes the following steps:

[0111] Step 1: The photovoltaic module is fed into the lead processing and backsheet glue application machine. The machine detects the angle of the busbar relative to the frame and the length of the busbar, and determines whether transparent tape or high-temperature tape was used during the lamination and sealing of the incoming module. The corresponding tape-removing mechanism is then used to remove the tape. The incoming module is then straightened and glued.

[0112] Specifically, the photovoltaic module is fed into the lead wire processing and backsheet glue application machine via a conveyor belt. At this time, the correction vision module 403 positions the busbar on the photovoltaic module and determines whether transparent tape or high-temperature tape is used when the incoming module is laminated and sealed according to the preset program.

[0113] If it is high-temperature tape, the double-blade adhesive tearing mechanism 406 will work. The double-blade body 209 will descend to the back panel of the photovoltaic module. After bonding, the heating module 409 will descend and bond to the top of the high-temperature tape, melting the EVA adhesive under the high-temperature tape. Then, the double-blade body 209 will scoop up the high-temperature tape from both sides. The clamping mechanism 203 of the double-blade body 209 will rise and clamp the high-temperature tape upward. While the high-temperature tape is being lifted upward, the double-blade body 209 will press the busbar into the guide groove of the pressing positioning block 226 to position and straighten the busbar.

[0114] If it is transparent tape, the single-blade tearing mechanism 407 will work, and the single-blade tearing mechanism 407 will directly tear the transparent tape from one end: the single blade body 306 will directly cut into the root of the manifold and then straighten it;

[0115] If it is a single-glass module with transparent tape, it needs to be used in conjunction with the auxiliary bonding mechanism 410. The auxiliary bonding mechanism 410 will slightly lift the busbar that is embedded in the back sheet due to lamination, and then straighten the busbar. After the busbar is straightened, the multi-directional moving module 402 will transport the components on the main functional mounting frame 404 forward along the Y-axis until the glue applicator 411 reaches above the busbar. At this time, due to the contraction of the recycling cylinder 416, the recycling trough 415 catches the components on the main functional mounting frame 404. When it reaches below the double-blade tearing mechanism 406 or the single-blade tearing mechanism 407, the clamping mechanism 203 will release and drop the torn high-temperature tape or transparent tape into the recycling trough 415. The glue applicator 411 will then perform uniform and stable glue application according to the pre-set glue application path. After the glue application is completed, the photovoltaic module is sent out by the conveyor frame 401.

[0116] Step Two: The junction boxes to be installed are fed into the integrated junction box installation machine via a feed tray mechanism. A robotic arm then picks up the junction boxes from the feed tray mechanism. A reciprocating mechanism positions and transports the junction boxes. The junction box installation mechanism positions and shapes the busbars from the glued photovoltaic modules and installs them onto the junction boxes.

[0117] Specifically, during the material loading process of the conveyor belt machine, when the lifting and positioning mechanism of the workstation is in the lower designated position, the lifting conveyor belt is flush with both the lower and rear conveyor belts. When the lifting and positioning mechanism of the workstation is in the upper designated position, a single blister pack can pass smoothly between the lifting conveyor belt and the lower conveyor belt. The lower conveyor belt can stack multiple blister packs. During startup, the clamping mechanism is located outside the blister packs. When the lifting mechanism lifts the first layer of blister packs, it lifts all the stacked blister packs. Then, the clamping mechanism moves inward to support the bottom of the second layer of blister packs. Afterward, the lifting mechanism descends until the first layer of blister packs is placed on the lower conveyor belt. Then, the first layer of blister packs is conveyed to the lifting conveyor belt, which is flush with the lower conveyor belt. Afterward, the lifting conveyor belt rises to the upper limit position, waiting for the robotic arm to remove the blister packs. Then, the lifting conveyor belt can directly convey the blister packs to the rear conveyor belt.

[0118] After the robotic arm takes the material from the blister pack, it positions and transports it to the designated workstation via a reciprocating mechanism.

[0119] During the junction box installation process, the junction box mounting mechanism's junction box pick-and-place module clamps the junction box in the reciprocating mechanism → the busbar shaping module is lowered to the middle of the busbar → the busbar shaping module positions and shapes the busbar → the junction box pick-and-place module aligns the junction box hole of the junction box with the busbar → the multi-directional installation and movement module slowly descends until the busbar passes through the junction box hole → the busbar shaping module retracts to avoid the junction box pick-and-place module → the junction box pick-and-place module presses down to the bottom, and after the junction box is installed in place, the junction box mounting mechanism moves backward, moves the busbar bending module above the junction box, and then lowers → the busbar bending module smooths the busbar parallel to the copper base plate of the junction box → the entire mechanism lifts to avoid the junction box. The specific structures of the busbar shaping module, the junction box pick-and-place module, and the busbar bending module can all adopt existing technologies, which will not be elaborated here.

[0120] Step 3: After installation, the photovoltaic modules enter the junction box laser welding machine. The junction box laser welding machine centers the photovoltaic modules. After centering, the machine takes the first photo and tightly attaches the photovoltaic module busbar to the copper base plate of the photovoltaic module junction box. Then, it takes the second photo. The junction box laser welding machine welds the busbar on the photovoltaic module junction box to the copper base plate in sequence according to the specified welding path.

[0121] Specifically: the photovoltaic module enters the junction box laser welding machine → the module alignment mechanism centers the photovoltaic module. After positioning, the visual positioning mechanism 107 moves above the photovoltaic module junction box to take the first picture. After the first picture is taken, the visual positioning mechanism 107 moves to the origin. The rotating pressing mechanism 106 presses the junction box precisely according to the correction data to tightly fit the photovoltaic module busbar with the copper base plate of the photovoltaic module junction box.

[0122] The visual positioning mechanism 107 moves to the top of the photovoltaic module junction box again to take a second picture. After the second picture is taken, the visual positioning mechanism 107 moves back to the original point, and the laser welding mechanism 105 moves. The laser 113 sequentially welds the busbar on the photovoltaic module junction box to the copper base plate according to the specified welding path. After the welding is completed, the visual positioning mechanism 107 moves to the top of the photovoltaic junction box to perform welding appearance inspection on the welded photovoltaic module junction box.

[0123] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above descriptions are merely specific embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for processing photovoltaic junction box leads and welding junction box installation, characterized in that: The photovoltaic junction box lead processing and junction box installation welding method is implemented by a photovoltaic junction box lead processing and junction box installation welding integrated machine. The photovoltaic junction box lead processing and junction box installation welding integrated machine includes a lead processing backplate glue application integrated machine (4) for straightening and glue application, a junction box installation integrated machine (11) for installing junction boxes (12) and busbars, and a junction box laser welding machine (1) for welding. The photovoltaic junction box lead processing and junction box installation welding method includes the following steps: Step 1: The photovoltaic module is fed into the lead processing backsheet glue applicator (4). The lead processing backsheet glue applicator detects the angle of the busbar relative to the frame and the length of the busbar and determines whether the incoming module is sealed with transparent tape or high temperature tape. The corresponding glue-removing mechanism is used to remove the glue. Then the incoming module is straightened and glued. Step 2: The junction box (12) to be installed is fed through the flow plate mechanism (5) in the junction box installation machine (11), and then the junction box is picked up by the robot arm mechanism (7). The reciprocating mechanism (8) positions and transports the junction box. The junction box installation mechanism (9) positions and shapes the busbar in the photovoltaic module after glue application, and installs the busbar to the junction box. Step 3: The installed photovoltaic module enters the junction box laser welding machine (1). The junction box laser welding machine centers the photovoltaic module. After centering, the first photo is taken and the photovoltaic module busbar is tightly attached to the copper base plate of the photovoltaic module junction box. Then the second photo is taken. The junction box laser welding machine welds the busbar on the photovoltaic module junction box to the copper base plate in sequence according to the specified welding path.

2. The photovoltaic junction box lead processing and junction box installation welding method according to claim 1, characterized in that: Step 1 is as follows: The photovoltaic module is fed into the lead wire processing backsheet glue application machine via a conveyor belt. At this time, the calibration vision module (403) positions the busbar on the photovoltaic module and determines whether transparent tape or high temperature tape is used when the incoming module is laminated and sealed according to the predetermined program. If it is a high-temperature tape, the double-blade tearing mechanism (406) will work. The double-blade body (209) will descend to the back panel of the photovoltaic module. After bonding, the heating module (409) will descend and bond to the top of the high-temperature tape, melting the EVA adhesive under the high-temperature tape. Then, the double-blade body (209) will scoop up the high-temperature tape from both sides. The clamping mechanism (203) of the double-blade body (209) will rise and clamp the high-temperature tape upward. While the high-temperature tape is being pulled upward, the double-blade body (209) will press the busbar into the guide groove of the pressing positioning block (226) to position and straighten the busbar. If it is transparent tape, the single-blade tearing mechanism (407) will work. The single-blade tearing mechanism (407) will directly tear the transparent tape from one end: the single blade body (306) will directly cut into the root of the manifold and then straighten it. If it is a single-glass component with transparent tape, it needs to be used with an auxiliary bonding mechanism (410). The auxiliary bonding mechanism (410) will slightly lift the busbar that is stuck in the back panel due to lamination, and then straighten the busbar. After the busbar is straightened, the multi-directional moving module (402) will transport the components on the main functional mounting bracket (404) forward along the Y-axis until the glue dispensing head of the glue dispensing mechanism (411) reaches above the busbar. The tape recycling mechanism includes a recycling tank 415 and a recycling cylinder 416. The recycling tank 415 is equipped with recycling cylinders 416 at both ends. The output of the recycling cylinder 416 is... The end is adapted to the multi-directional moving module 402 for installation. At this time, due to the contraction of the recycling cylinder (416), the recycling trough (415) catches the components on the main functional mounting frame (404). When it reaches the double-blade tearing mechanism (406) or the single-blade tearing mechanism (407), the clamping mechanism (203) will release and drop the torn high-temperature tape or transparent tape into the recycling trough (415). The glue applicator (411) then performs uniform and stable glue applicator according to the pre-set glue applicator path. After the glue applicator is completed, the photovoltaic module is sent out by the conveyor frame (401).

3. The photovoltaic junction box lead processing and junction box installation welding method according to claim 1, characterized in that: Step two is as follows: During the material loading process of the conveyor belt mechanism, when the lifting and positioning mechanism of the working position is in the lower designated position, the lifting conveyor belt is flush with the lower conveyor belt and the rear conveyor belt respectively. When the lifting and positioning mechanism of the working position is in the upper designated position, a single blister box can pass smoothly between the lifting conveyor belt and the lower conveyor belt. The lower conveyor belt can stack multiple blister boxes. When started, the dragging and clamping mechanism is outside the blister box. When the lifting mechanism lifts the first layer of blister boxes, it lifts all the stacked blister boxes. Then the dragging and clamping mechanism moves inward to support the bottom of the second layer of blister boxes. After that, the lifting mechanism descends until the first layer of blister boxes is placed on the lower conveyor belt. Then the first layer of blister boxes is conveyed to the lifting conveyor belt that is flush with the lower conveyor belt. After that, the lifting conveyor belt rises to the upper limit position, waiting for the robot arm mechanism to pick up the material from the blister box. After that, the lifting conveyor belt can directly convey the blister box to the rear conveyor belt. After the robotic arm picks up the material from the blister pack, it positions and transports it to the designated workstation via a reciprocating mechanism. During junction box installation, the junction box mounting mechanism's junction box pick-and-place module clamps the junction box in the reciprocating mechanism → the busbar shaping module lowers to the middle of the busbar → the busbar shaping module positions and shapes the busbar → the junction box pick-and-place module aligns the junction box hole of the junction box with the busbar → the multi-directional installation and movement module slowly descends until the busbar passes through the junction box hole → the busbar shaping module retracts to avoid the junction box pick-and-place module → the junction box pick-and-place module presses down to the bottom, and after the junction box is installed in place, the junction box mounting mechanism moves backward, moves the busbar bending module above the junction box, and then lowers → the busbar bending module smooths the busbar parallel to the copper base plate of the junction box → the entire mechanism lifts to avoid the junction box.

4. The photovoltaic junction box lead processing and junction box installation welding method according to claim 1, characterized in that: Step 3 is as follows: the photovoltaic module enters the junction box laser welding machine → the module alignment mechanism centers the photovoltaic module. After the positioning is completed, the visual positioning mechanism (107) moves to the top of the photovoltaic module junction box to take the first picture. After the first picture is taken, the visual positioning mechanism (107) moves to the origin. The rotating pressing mechanism (106) presses the junction box precisely according to the correction data to tightly fit the photovoltaic module busbar with the copper base plate of the photovoltaic module junction box. The visual positioning mechanism (107) moves to the top of the photovoltaic module junction box again to take a second picture. After the second picture is taken, the visual positioning mechanism (107) moves back to the original point, and the laser welding mechanism (105) moves. The laser (113) sequentially welds the busbar on the photovoltaic module junction box to the copper base plate according to the specified welding path. After the welding is completed, the visual positioning mechanism (107) moves to the top of the photovoltaic junction box to perform welding appearance inspection on the welded photovoltaic module junction box.

5. A photovoltaic junction box lead processing and junction box installation and welding integrated machine employing the installation and welding method described in any one of claims 1-4, characterized in that, The junction box installation machine includes a feed plate mechanism (5) for loading junction boxes, a robotic arm mechanism (7) for gripping junction boxes (12) on the feed plate mechanism, a reciprocating mechanism (8) for positioning and conveying junction boxes, a positioning vision mechanism (10) for positioning the busbar position on the photovoltaic module, and a junction box installation mechanism (9) for installing the junction box and busbar. The flow plate mechanism (5) includes a flow plate machine frame, and a lower conveyor belt (501), a lifting conveyor belt (502) and a rear conveyor belt (503) arranged in sequence within the flow plate machine frame. The lifting conveyor belt is equipped with a working position lifting and positioning mechanism (509). The lower conveyor belt is equipped with a blister box (6) for positioning the junction box body, junction box plug and junction box wire. The blister box (6) includes a blister box body (61) and at least one photovoltaic junction box placement cavity mechanism disposed on the blister box body. Each of the photovoltaic junction box placement cavity mechanisms includes a junction box body placement cavity (62), a junction box plug placement cavity (63), and a junction box wire placement cavity (64).

6. The photovoltaic junction box lead processing and junction box installation welding integrated machine according to claim 5, characterized in that: The integrated lead wire processing and backsheet adhesive application machine includes a conveyor frame (401), a multi-directional moving module (402), a correction vision module (403), a main function mounting frame (404), and an adhesive application energy storage device (405). The conveyor frame (401) is used to transport photovoltaic modules. A tape recycling mechanism is provided on one side of the conveyor frame (401). The correction vision module (403) and the multi-directional moving module (402) are respectively provided on the conveyor frame (401). The correction vision module (403) is used to position the busbars on the photovoltaic modules. The multi-directional moving module (402) can drive the main function mounting frame (404). The main functional mounting frame (404) is equipped with movable double-blade adhesive tearing mechanism (406), single-blade adhesive tearing mechanism (407), vision inspection module (408), heating module (409), auxiliary bonding module (410) and adhesive dispensing mechanism (411). The movement of the double-blade adhesive tearing mechanism (406), single-blade adhesive tearing mechanism (407), vision inspection module (408), heating module (409), auxiliary bonding module (410) and adhesive dispensing mechanism (411) does not interfere with each other. An adhesive dispensing energy storage device (405) is provided above the main functional mounting frame (404).

7. The photovoltaic junction box lead processing and junction box installation welding integrated machine according to claim 6, characterized in that: The double-blade adhesive-tearing mechanism (406) includes a straightening adhesive-tearing mounting plate (201), a moving adjustment mechanism (202), a clamping mechanism (203), an elastic pressing component (204), and a double-blade assembly (205). A Z-axis lifting module (412) is provided on one side of the main functional mounting frame (404). The straightening adhesive-tearing mounting plate (201) is fixedly mounted at the lower end of the Z-axis lifting module (412). The moving adjustment mechanism (202) is fixedly mounted on the straightening adhesive-tearing mounting plate (201). A clamping mechanism (203) is provided below the moving adjustment mechanism (202). An elastic pressing component (204) is provided at the lower end of the clamping mechanism (203). Double-blade assemblies (205) are symmetrically arranged on both sides of the elastic pressing component (204). The double-blade assembly (205) includes a double-blade fixing block (206), a double-blade adjusting block (207), and a double-blade rotating shaft. (208), double shovel body (209) and double shovel spring (210), the side of the moving adjustment mechanism (202) is fixedly connected to the upper end of the double shovel fixing block (206), the double shovel fixing block (206) is "L" shaped, the lower part of the double shovel fixing block (206) is provided with an adjustment screw (211), one end of the adjustment screw (211) is connected to the double shovel adjusting block (207), the bottom of the double shovel adjusting block (207) is fixed to the inner side of the double shovel fixing block (206), the double shovel rotating shaft (208) is provided inside both sides of the double shovel adjusting block (207), the double shovel rotating shaft (208) is movably connected to the double shovel body (209), the double shovel body (209) is abutted on the double shovel body (209), and the other end of the double shovel spring (210) abuts on the double shovel adjusting block (207).

8. The photovoltaic junction box lead processing and junction box installation welding integrated machine according to claim 7, characterized in that: The single-blade adhesive-tearing mechanism (407) includes an adhesive-tearing mounting top plate (301), a Z-axis slide cylinder (302), a Y-axis slide cylinder (303), a single-blade fixing block (304), a single-blade adjusting block (305), and a single-blade body (306). An adhesive-tearing mounting base plate (413) is provided on the outer side of the Z-axis lifting module (412). The front side of the adhesive-tearing mounting base plate (413) is connected to the adhesive-tearing mounting top plate (301). A Z-axis slide cylinder (302) that moves along the Z-axis direction is fixedly mounted on the upper end of the adhesive-tearing mounting top plate (301). A Y-axis slide cylinder (303) is fixedly mounted on one side of the lower end of the adhesive-tearing mounting top plate (301). The output end of the Y-axis slide cylinder (303) is adapted and connected to the upper end of the single-blade fixing block (304). A single-blade adjusting block (305) is fixedly mounted on the lower end of the single-blade fixing block (304). A mounting groove is provided in the blade adjusting block (305), and a single blade body (306) is rotatably mounted in the mounting groove. One end of the single blade body (306) is adapted to be connected to the output end of a small cylinder (307) through a top column (312). The small cylinder (307) is fixed to the inner side of the upper surface of the single blade adjusting block (305). A second air pipe connector (308) is provided on the outer side of the single blade adjusting block (305). The lower end of the second air pipe connector (308) is connected to the mounting groove. A single blade rotating shaft (311) is provided in the mounting groove. The single blade rotating shaft (311) passes through the single blade body (306) and is rotatably connected to it. A clamping block (309) is provided at one bottom end of the single blade adjusting block (305). The lower end of the clamping block (309) can be contacted and connected to the other end of the single blade body (306).

9. The photovoltaic junction box lead processing and junction box installation welding integrated machine according to claim 5, characterized in that: The junction box laser welding machine includes a frame (101), a conveying mechanism (102), a straightening mechanism (103), a lifting mechanism (104), a laser welding mechanism (105), a rotating pressing mechanism (106), and a visual positioning mechanism (107). The frame (101) is provided with a conveying mechanism (102). The conveying mechanism (102) is provided with straightening mechanisms (103) on both sides and a lifting mechanism (104) sliding at the bottom. The upper end of the frame (101) is provided with a laser welding mechanism (105) and a rotating pressing mechanism (106) sliding relative to each other. The visual positioning mechanism (107) is provided parallel below the laser welding mechanism (105). The bottom of the visual positioning mechanism (107) is higher than the bottom of the rotating pressing mechanism (106).

10. The photovoltaic junction box lead processing and junction box installation welding integrated machine according to claim 9, characterized in that: The laser welding mechanism (105) includes a laser X-axis module (108), a fixed top plate (109), a laser head side plate (110), a laser head mounting plate (111), a laser Z-axis module (112), and a laser (113). The laser X-axis module (108) is fixedly installed on the upper end of the frame (101). The fixed top plate (109) is slidably connected to the laser X-axis module (108). The laser head side plates (110) are fixed on both sides of the fixed top plate (109). The lower end of the laser head side plate (110) bends forward and extends parallel to the fixed top plate (109). One end of the laser head side plate (110) and one end of the fixed top plate (109) are fixedly connected to the back side of the laser head mounting plate (111). The laser Z-axis module (112) is fixedly installed on the front side of the laser head mounting plate (111). The laser (113) is slidably connected to the laser Z-axis module (112).

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