A visual monitoring system and method for the glue output ratio of components A and B

Abstract

The present invention relates to a visual monitoring system and method for the glue output ratio of components A and B. The present invention includes installing at least one liquid flow detection device on the glue output hose lines of components A and B, respectively, each liquid flow detection device is connected to a control device, and the control device is connected to an alarm device; the qualified impeller speed range of each of the glue output hoses of group A and group B and the qualified speed ratio range of each impeller of each of the glue output hoses of group A and group B are preset respectively; the glue passes through the impellers of each of the glue output hoses of group A and group B and drives the impellers to rotate, and the speed data of the second gear is obtained in real time through the speed processing module; the control device compares the impeller speed data with the corresponding preset qualified impeller speed range in real time, and judges whether there is an abnormality in the liquid flow based on the comparison result. If there is an abnormality, the alarm device will sound an alarm. The present invention can monitor the glue output amount and glue output ratio of components A and B in real time.

Description

Technical Field

[0001] The present invention relates to the technical field of photovoltaic module manufacturing, and in particular to a visual monitoring system and method for the glue discharge ratio of components A and B. Background Art

[0002] In the photovoltaic module industry, junction boxes rely on potting compound to protect the electronic components within, providing thermal conductivity, insulation, flame retardancy, and waterproofing. Currently, potting compound is divided into two types: component A and component B. After mixing components A and B in appropriate proportions, they cure under suitable temperature and humidity conditions. Component B is the key to curing. Excessive or insufficient component B—that is, an unsuitable ratio of components A to B—can lead to curing anomalies after mixing, impacting the reliability of the photovoltaic module.

[0003] There are two existing quality inspection methods in the industry. The first is the weighing measurement method: every 4 hours, weigh the A and B component glues discharged once to determine whether their ratio is qualified. The second is the sample observation method. After mixing the A and B component glues discharged once, wait for 15 to 20 minutes to observe their surface drying conditions, and wait for 2 hours to observe their curing conditions. Based on the above two observation conclusions, determine whether the ratio of the A and B component glues discharged once is qualified. Both methods require personnel to perform additional sampling operations. The sampling and conclusion judgment process is cumbersome, which affects production efficiency. In addition, when using the second method for judgment, it is found that the problem cycle is long. While waiting for the results, the production line continues to produce. Therefore, the lag of this detection method is too strong, and abnormalities cannot be controlled in time. There is a hidden danger of reliability abnormalities in large quantities of components. Summary of the Invention

[0004] To this end, the present invention provides a visual monitoring system and method for the glue output ratio of components A and B, which can monitor the glue output amount and glue output ratio of components A and B in real time, and realize timely discovery and resolution of abnormal conditions.

[0005] In order to solve the above technical problems, the present invention provides a liquid flow detection device, comprising:

[0006] A cavity-type container shell having a hose connection port;

[0007] An impeller is disposed in the cavity container housing and is located beside the hose connection port, and is capable of rotating under the propulsion of the liquid;

[0008] The housing of the rotation number amplifying device is connected to the housing of the cavity container, and the housing of the rotation number amplifying device is provided with:

[0009] A main shaft, one end of which is connected to the center of the impeller and rotates around itself as the impeller rotates;

[0010] a first gear, the center of which is connected to the other end of the main shaft, the first gear having the same rotation speed as the impeller and provided with internal teeth;

[0011] a second gear having external teeth meshing with the internal teeth of the first gear;

[0012] a laser emitting module disposed beside the second gear, the laser emitting module comprising a laser emitting end and a laser receiving end, wherein the teeth of the second gear are capable of intermittently blocking the laser emitted from the laser emitting end to the laser receiving end when the second gear rotates;

[0013] A revolution processing module and a signal transmitting module connected thereto, wherein the revolution processing module is used to obtain the tooth signal and transmit it to the control module through the signal transmitting module for processing to obtain the revolution of the second gear, and the revolution of the first gear and the impeller is obtained based on the revolution of the second gear.

[0014] In one embodiment of the present invention, the first gear has the same number of rotations as the impeller.

[0015] In one embodiment of the present invention, the cavity-type container shell is a transparent structure.

[0016] In one embodiment of the present invention, the liquid flow detection device is included.

[0017] The present invention also provides a visual monitoring system for the glue output ratio of components A and B. Liquid flow detection devices are respectively installed on the glue output hose lines of components A and B. Each of the liquid flow detection devices is connected to a control device, and the control device is connected to an alarm device.

[0018] The present invention also provides a method for visually monitoring the glue discharge ratio of components A and B. At least one liquid flow detection device is installed on the glue discharge hose line of components A and B, respectively. Each of the liquid flow detection devices is connected to a control device, and the control device is connected to an alarm device.

[0019] According to the qualified glue output range of group A and group B, the qualified impeller speed range of group A and group B glue output pipes and the qualified impeller speed ratio range of group A and group B glue output pipes are preset respectively;

[0020] The glue passes through the impellers on the glue outlet pipes of group A and group B and drives the impellers to rotate. The speed processing module obtains the speed data of the second gear in real time, and obtains the speed data of the impeller based on the speed data of the second gear.

[0021] The control device compares the impeller rotation data with the corresponding preset qualified impeller rotation range in real time, and determines whether there is an abnormality in the liquid flow based on the comparison result. If there is an abnormality, the alarm device will sound an alarm.

[0022] In one embodiment of the present invention, the determining whether the liquid flow rate is abnormal and, if so, the alarm device issuing an alarm, includes:

[0023] When the impeller revolutions on the rubber outlet pipe of group A, the impeller revolutions on the rubber outlet pipe of group B, and the ratio of the impeller revolutions on the rubber outlet pipes of group A to group B are all 0, it is a standby state and the alarm device does not sound an alarm;

[0024] When the speed of the impeller on the rubber outlet pipe of group A or the speed of the impeller on the rubber outlet pipe of group B is 0, the surface rubber pipe is blocked and the alarm device sends out a first-level alarm;

[0025] When either the impeller speed on the glue outlet pipe of group A or the impeller speed on the glue outlet pipe of group B is outside the qualified impeller speed range, or when the impeller speed ratio of the impellers on the glue outlet pipes of group A and group B is outside the qualified speed ratio range, the alarm device issues a second-level alarm.

[0026] In one embodiment of the present invention, the first level alarm intensity is greater than the second level alarm intensity.

[0027] In one embodiment of the present invention, a digital display device connected to the control device is further included, and the digital display device is used to display the number of revolutions of the impellers in the respective liquid flow detection devices on the group A rubber outlet pipes and the group B rubber outlet pipes in real time.

[0028] In one embodiment of the present invention, the control device adopts PLC.

[0029] In one embodiment of the present invention, the glue passes through the impellers on the glue outlet pipes of group A and the glue outlet pipes of group B and drives the impellers to rotate, including:

[0030] The glue filling port is opened and glue begins to flow out, and the impeller is pushed by the glue and starts to rotate;

[0031] The glue filling port is closed and the glue discharging is completed. One glue discharging process lasts for 3 seconds. The number of revolutions of the impeller is obtained only during the discharging time.

[0032] The above technical solution of the present invention has the following advantages over the prior art:

[0033] The present invention discloses a visual monitoring system and method for the discharge ratio of components A and B. By installing at least one cavity container with a built-in impeller on the discharge hoses of components A and B, the impeller inside can be observed through the outer wall of the container. The system observes whether the impeller is rotated by the discharge action, thereby visualizing the discharge of components A and B.

[0034] In the present invention, the impeller speed value directly reflects the glue output of each component glue and the glue output ratio of components A and B, thereby realizing the visualization of the glue output ratio of components A and B.

[0035] In the present invention, the impeller is linked with the rotation speed processing module and the alarm device. By recording the impeller rotation speed of each component A and component B glue, it is judged whether the glue output ratio of component A and component B glue is within the qualified range. If the glue output ratio is abnormal, the alarm device will immediately alarm to remind personnel to come to investigate and deal with the abnormality.

[0036] In the present invention, production personnel can quickly identify the category of abnormal glue and determine the type of abnormality (hose blockage, excessive glue output or insufficient glue output) based on the rotational speed of the impellers of components A and B, so as to quickly respond to different abnormal situations, save time for abnormality handling, and reduce scrapping and cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In order to make the contents of the present invention more clearly understood, the present invention is further described in detail below based on specific embodiments of the present invention in conjunction with the accompanying drawings.

[0038] Figure 1 It is a schematic diagram of the visualized monitoring system for the glue output ratio of components A and B of the present invention.

[0039] Figure 2 This is the overall flow chart of the visualized method for monitoring the glue output ratio of components A and B of the present invention.

[0040] Figure 3 The present invention is a flow chart of a method for monitoring the glue output ratio of components A and B using a PLC control visualization.

[0041] Figure 4 It is a schematic cross-sectional view of the structure of the liquid flow detection device of the present invention.

[0042] Figure 5 It is a schematic diagram of the gear meshing structure in the liquid flow detection device of the present invention.

[0043] Figure 6 It is a schematic diagram of the arrangement of the laser emission module and the revolution processing module in the liquid flow detection device of the present invention.

[0044] Description of the accompanying drawings:

[0045] 1. Cavity container shell; 11. Hose connection port;

[0046] 2. Impeller;

[0047] 3. Housing of the revolution amplifying device;

[0048] 4. Main shaft;

[0049] 5. First gear;

[0050] 6. Second gear;

[0051] 7. Laser emission module;

[0052] 8. Revolution processing module. DETAILED DESCRIPTION

[0053] The present invention will be further described below with reference to the accompanying drawings and specific embodiments so that those skilled in the art can better understand the present invention and implement it. However, the embodiments are not intended to limit the present invention.

[0054] In the present invention, if directions (up, down, left, right, front and back) are described, it is only for the convenience of describing the technical solution of the present invention, and does not indicate or imply that the technical features referred to must have a specific orientation, be constructed and operate in a specific orientation. Therefore, it cannot be understood as a limitation of the present invention.

[0055] In the present invention, "several" means one or more, "multiple" means more than two, "greater than," "less than," "exceeds," etc. are understood to exclude the number itself; "above," "below," "within," etc. are understood to include the number itself. In the description of the present invention, the use of "first" or "second" is solely for the purpose of distinguishing technical features and is not to be construed as indicating or implying relative importance, implicitly specifying the number of the indicated technical features, or implicitly specifying the order of the indicated technical features.

[0056] In the present invention, unless otherwise expressly defined, terms such as "disposed," "installed," and "connected" should be interpreted broadly. For example, they may refer to direct connection or indirect connection through an intermediate medium; fixed connection or detachable connection or integral molding; mechanical connection or electrical connection or mutual communication; and internal connection between two components or interaction between two components. Those skilled in the art can reasonably determine the specific meanings of the above terms in the present invention based on the specific content of the technical solution.

[0057] Reference Figure 2 and Figure 3 As shown, a visual method for monitoring the glue output ratio of components A and B includes the following steps:

[0058] S1. Install at least one liquid flow detection device on the glue discharge hose lines of group A and group B, respectively. Each liquid flow detection device is connected to a control device, and the control device is connected to an alarm device;

[0059] S2. Preset the qualified impeller 2 speed ranges of the glue outlet pipes of group A and group B and the qualified impeller 2 speed ratio ranges of the impellers 2 of the glue outlet pipes of group A and group B respectively based on the qualified glue output ranges of the glue outlet pipes of group A and group B; the glue passes through the impellers 2 of the glue outlet pipes of group A and group B and drives the impellers 2 to rotate, and the speed processing module 8 obtains the speed data of the second gear 6 in real time, and obtains the speed data of the impeller 2 based on the speed data of the second gear 6;

[0060] S3, the control device compares the rotation speed data of the impeller 2 with the corresponding preset qualified impeller 2 rotation speed range in real time, and determines whether there is an abnormality in the liquid flow based on the comparison result. If there is an abnormality, the alarm device issues an alarm;

[0061] S4. Production personnel come to handle the abnormality according to the alarm, determine which hose has the abnormality based on the rotational speed, and complete the treatment quickly.

[0062] The above method uses a visual monitoring system for the glue output ratio of components A and B, referring to Figure 1 As shown, the liquid flow detection devices are respectively installed on the glue hose lines of group A and group B. Each of the liquid flow detection devices is connected to a control device, and the control device is connected to an alarm device. The control device can adopt a PLC controller, and the alarm device adopts an audible and visual alarm, a buzzer, etc.

[0063] Reference Figures 4 to 6 As shown, in this embodiment, the liquid flow detection device includes:

[0064] The cavity-type container housing 1 has a hose connection port 11 connected to the rubber outlet hoses of group A and group B;

[0065] The impeller 2 is disposed in the cavity container housing 1 and is located beside the hose connection port 11 and is capable of rotating under the propulsion of the liquid;

[0066] The rotation number amplifying device housing 3 is connected to the cavity container housing 1, and the rotation number amplifying device housing 3 is provided with:

[0067] The main shaft 4 has one end connected to the center of the impeller 2 and rotates around itself when the impeller 2 rotates;

[0068] A first gear 5, the center of which is connected to the other end of the main shaft 4, the first gear 5 has the same rotation speed as the impeller 2 and is provided with internal teeth;

[0069] a second gear 6 provided with external teeth meshing with the internal teeth of the first gear 5;

[0070] a laser emitting module 7 disposed beside the second gear 6, comprising a laser emitting end and a laser receiving end. When the second gear 6 rotates, the teeth of the laser emitting module 7 can intermittently block the laser emitted from the laser emitting end to the laser receiving end, thereby forming a tooth signal;

[0071] The speed processing module 8 and the signal transmitting module connected thereto (which may also be built into the speed processing module 8) are used to obtain the tooth signal and transmit it to the control module through the signal transmitting module for processing to obtain the speed of the second gear 6. The speed of the first gear 5 and the impeller 2 is obtained based on the speed of the second gear 6.

[0072] Among them, the first gear 5 has the same number of revolutions as the impeller 2; the cavity-type container shell 1 is sealed at the top and bottom (to show the internal structure, its upper surface is not shown in the figure); the installation method on the glue discharge hose line is preferably directly connected in series in the hose line, and a flange connection can be used to connect the upper section of the hose to the hose close to the discharge barrel side, and connect the lower section of the hose to the hose close to the glue filling port side.

[0073] The gear ratio of the second gear 6 to the first gear 5 is 1:4, that is, the first gear 5 rotates 1 circle, which drives the second gear 6 to rotate 4 circles, achieving the effect of amplifying the number of revolutions; the laser emitting module 7 is a laser emitter that emits laser at one end and receives laser at the other end. As the second gear 6 rotates, the teeth will block the laser path, resulting in the inability to receive laser. The laser module transmits information such as laser and no laser to the number of revolutions processing module 8; the number of revolutions processing module 8 receives the signal transmitted by the laser module, integrates one with laser and one without laser into a set of tooth signals, and is provided with a signal transmitting module to transmit the tooth signals to the control device. The control device processes and calculates the sum of the tooth signals and divides it by the number of teeth of the second gear 6 to obtain the number of revolutions of the second gear 6; the number of revolutions processing module 8 can adopt a microcontroller (MCU), and the signal transmitting module is a 4G signal transmitting module or a 5G signal transmitting module.

[0074] In some embodiments, the cavity container shell 1 is a transparent structure, and the internal impeller 2 can be observed through the outer wall of the container; it is observed whether the impeller 2 is driven to rotate by the glue discharge action to achieve visualization of the glue discharge of components A and B.

[0075] In one embodiment of the present invention, the determining whether the liquid flow rate is abnormal and, if so, the alarm device issuing an alarm, includes:

[0076] When the impeller 2 revolutions on the rubber outlet pipe of group A, the impeller 2 revolutions on the rubber outlet pipe of group B, and the ratio of the impeller 2 revolutions on the rubber outlet pipes of group A and group B are all 0, it is in standby state and the alarm device does not sound an alarm;

[0077] When the speed of impeller 2 on the rubber outlet pipe of group A or the speed of impeller 2 on the rubber outlet pipe of group B is 0, the rubber pipe is blocked and the alarm device sends out a first-level alarm;

[0078] When either the speed of the impeller 2 on the glue outlet pipe of group A or the speed of the impeller 2 on the glue outlet pipe of group B is outside the qualified impeller 2 speed range, or the speed ratio of the impeller 2 on the glue outlet pipes of group A and group B is outside the qualified speed ratio range, the alarm device issues a second-level alarm.

[0079] In one embodiment of the present invention, the first level alarm intensity is greater than the second level alarm intensity, and the alarm signals such as the light intensity and volume of the alarm light are different according to the different abnormality levels.

[0080] In this embodiment, a digital display device connected to the control device is also included. The digital display device is used to display in real time the number of revolutions of the impeller 2 in the liquid flow detection device on each of the group A rubber outlet pipe and the group B rubber outlet pipe. The number of revolutions of the second gear 6 can also be displayed on the digital display device, so that the speed value of the impeller 2 intuitively reflects the amount of glue discharged from each component glue and the glue discharge ratio of the A and B components glue, thereby realizing the visualization of the glue discharge ratio of the A and B components glue.

[0081] In this embodiment, in the control device, the upper and lower limit values ​​of the impeller 2 rotation speed are inputted correspondingly according to the type of glue.

[0082] The glue filling port is opened, glue starts to flow out, and the impeller 2 is pushed by the glue and starts to rotate.

[0083] The glue filling port is closed and the glue discharge is completed. One glue discharge process lasts for 3 seconds. The number of revolutions of impeller 2 is calculated only during the discharge time.

[0084] After the discharge is completed, the number of revolutions of the impeller 2 during the discharge time will be transmitted to the control module. If the number of revolutions exceeds the set qualified range, an alarm will be triggered.

[0085] The production staff comes to handle the abnormality and judges the range of the abnormality according to the value on the digital display device. After the abnormality is handled, the alarm device is reset and the next glue filling operation is continued.

[0086] Specifically, in the case of one-time glue discharge, the glue discharge volume of group A is 10.6-17.5cm 3 , the glue volume of component B is 1.3-2.3cm 3 , the inner diameter of the rubber hose is 6mm, the diameter of the blade is 4mm, and the gear ratio of the first gear 5 to the second gear 6 is 4:1.

[0087] The qualified revolution range of component A glue is: 50.011-0.018 revolutions of the first gear and 60.045-0.074 revolutions of the second gear;

[0088] The qualified revolution range of component B glue is: 50.001-0.002 revolutions for the first gear and 60.006-0.010 revolutions for the second gear;

[0089] The ratio of qualified glue revolutions of group A and group B is: 4.52-12.98:1;

[0090] Since the number of revolutions per glue discharge is still small even after being amplified by 4 times, further amplification can be considered, or the number of revolutions can be monitored once for a total of 10 or 20 glue discharges; if the number of revolutions or the ratio of the number of revolutions is not within the qualified range, the control device triggers the alarm device to alarm.

[0091] Through the above method, production personnel can quickly identify the abnormal glue category and determine the abnormal type (hose blockage, excessive glue output or insufficient glue output) according to the rotation speed of the A and B component glue impellers, so as to quickly respond to different abnormal situations, save time for abnormal processing, and reduce scrap and save costs.

[0092] Finally, it should be noted that the above specific implementation methods are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to examples, those skilled in the art should understand that the technical solutions of the present invention can be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A visual method for monitoring the glue output ratio of components A and B, characterized in that: include: At least one liquid flow detection device is installed on the glue pipe line of group A and group B respectively, and each of the liquid flow detection devices is connected to a control device, and the control device is connected to an alarm device; The liquid flow detection device comprises: A cavity-type container shell having a hose connection port; An impeller is disposed in the cavity container housing and is located beside the hose connection port, and is capable of rotating under the propulsion of the liquid; The housing of the rotation number amplifying device is connected to the housing of the cavity container, and the housing of the rotation number amplifying device is provided with: A main shaft, one end of which is connected to the center of the impeller and rotates around itself as the impeller rotates; a first gear, the center of which is connected to the other end of the main shaft, the first gear having the same rotation speed as the impeller and provided with internal teeth; a second gear having external teeth meshing with the internal teeth of the first gear; a laser emitting module disposed beside the second gear, the laser emitting module comprising a laser emitting end and a laser receiving end, wherein the teeth of the second gear are capable of intermittently blocking the laser emitted from the laser emitting end to the laser receiving end when the second gear rotates; a revolution processing module and a signal transmitting module connected thereto, the revolution processing module being used to obtain a tooth signal and transmit the signal to the control device through the signal transmitting module for processing to obtain the revolution of the second gear, and to obtain the revolutions of the first gear and the impeller based on the revolution of the second gear; According to the qualified glue output range of group A and group B, the qualified impeller speed range of group A and group B glue output pipes and the qualified impeller speed ratio range of group A and group B glue output pipes are preset respectively; The glue passes through the impellers on the glue outlet pipes of group A and group B and drives the impellers to rotate. The speed processing module obtains the speed data of the second gear in real time, and obtains the speed data of the impeller based on the speed data of the second gear. The control device compares the impeller rotation data with the corresponding preset qualified impeller rotation range in real time, and determines whether the liquid flow is abnormal based on the comparison result. If there is an abnormality, the alarm device issues an alarm; The determining whether the liquid flow rate is abnormal and, if so, the alarm device issuing an alarm, includes: When the impeller revolutions on the rubber outlet pipe of group A, the impeller revolutions on the rubber outlet pipe of group B, and the ratio of the impeller revolutions on the rubber outlet pipes of group A to group B are all 0, it is a standby state and the alarm device does not sound an alarm; When either the impeller revolutions of the rubber outlet pipe of group A or the impeller revolutions of the rubber outlet pipe of group B reaches 0, the rubber outlet pipe is blocked and the alarm device issues a first-level alarm. When either the impeller speed on the glue outlet pipe of group A or the impeller speed on the glue outlet pipe of group B is not within the qualified impeller speed range, or when the ratio of the impeller speeds on the glue outlet pipes of group A and group B is not within the qualified speed ratio range, the alarm device issues a second-level alarm.

2. A visual method for monitoring the glue discharge ratio of components A and B according to claim 1, characterized in that: The first level alarm intensity is greater than the second level alarm intensity.

3. A visual method for monitoring the glue discharge ratio of components A and B according to claim 1, characterized in that: It also includes a digital display device connected to the control device, and the digital display device is used to display the number of revolutions of the impellers in the respective liquid flow detection devices on the group A rubber outlet pipes and the group B rubber outlet pipes in real time.

4. A visual method for monitoring the glue discharge ratio of components A and B according to claim 1, characterized in that: The control device adopts PLC.

5. A visual method for monitoring the glue discharge ratio of components A and B according to claim 1, characterized in that: The glue passes through the impellers on the glue outlet pipes of group A and group B and drives the impellers to rotate, including: The glue filling port is opened and glue begins to flow out, and the impeller is pushed by the glue and starts to rotate; The glue filling port is closed and the glue discharging is completed. One glue discharging process lasts for 3 seconds. The number of revolutions of the impeller is obtained only during the discharging time.

6. A visual method for monitoring the glue discharge ratio of component A and component B according to claim 1, characterized in that: The first gear has the same number of rotations as the impeller.

7. A visual method for monitoring the glue discharge ratio of component A and component B according to claim 1, characterized in that: The cavity-shaped container shell is a transparent structure.

8. A visual monitoring system for the glue output ratio of components A and B, characterized in that: A method for visually monitoring the glue discharge ratio of components A and B as described in any one of claims 1 to 7 is provided, wherein the monitoring system includes a liquid flow detection device, and liquid flow detection devices are respectively installed on the glue discharge hose lines of component A and component B. Each of the liquid flow detection devices is connected to a control device, and the control device is connected to an alarm device.

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