Laminator with automatic pressure detection function and laminating monitoring method

Abstract

The application relates to a laminating machine with automatic pressure detection function and a laminating monitoring method, and relates to the technical field of laminating machines.The method comprises the following steps: laying multiple photovoltaic modules on a heating plate; closing the upper cover of the laminating machine; using an air pump to vacuumize the upper cavity and the lower cavity; pressurizing the upper cavity multiple times to laminate the photovoltaic modules; keeping the pressure after each pressurization for a certain time; a pressure sensor measures the pressure sensing data after pressurization, and sends the pressure sensing data to an industrial computer; the industrial computer receives multiple pressure sensing data, inputs the pressure sensing data into a preset pressure monitoring model according to pressure detection positions and pressure detection times, and obtains pressure change curves of different points. The application has the effects of monitoring the pressure state of laminated photovoltaic modules of the laminating machine, and timely and effectively troubleshooting abnormal photovoltaic modules.

Description

Technical Field

[0001] This application relates to the field of laminator technology, and in particular to a laminator with automatic pressure detection function and a lamination monitoring method. Background Technology

[0002] The lamination process is one of the important steps in the photovoltaic module manufacturing process. The lamination process mainly uses a laminator to heat, vacuum and pressurize the laid modules in the laminator cavity, so that the ethylene-vinyl acetate copolymer (EVA) of the module melts and bonds the cells, glass and backsheet together, sealing the photovoltaic module.

[0003] In related technologies, a laminator includes a top cover, a silicone plate, and a heating base plate for heating photovoltaic modules. A lower chamber is formed between the heating base plate and the silicone plate for placing the photovoltaic modules. The silicone plate and the top cover form an upper chamber. By evacuating the lower chamber, air and volatiles between the photovoltaic module materials in the lower chamber are removed, eliminating air bubbles in the photovoltaic modules. By evacuating the upper chamber, a pressure difference is generated in the upper chamber of the laminator, and the upper chamber is inflated to generate the pressure required in the lamination process, thereby pressurizing the photovoltaic modules.

[0004] Typically, a laminator can laminate multiple photovoltaic (PV) modules at once. The PV modules are arranged sequentially in the lower chamber, and the silicone pad simultaneously pressurizes multiple PV modules. However, during operation, due to the different positions of the vents, the overall air pressure distribution in the upper chamber may be uneven, resulting in varying degrees of inflation on the silicone pad. This can cause inconsistent pressure on each PV module from the silicone pad. If this is not identified in time, lamination abnormalities may occur in individual PV modules. The inability to address these abnormal PV modules promptly can lead to overall substandard quality of the PV modules. Summary of the Invention

[0005] In order to monitor the pressure status of photovoltaic modules laminated by the laminator and to promptly and effectively identify abnormal photovoltaic modules, this application provides a laminator with automatic pressure detection function and a lamination monitoring method.

[0006] In a first aspect, this application provides a laminator with automatic pressure detection function, employing the following technical solution: A laminator with automatic pressure detection function includes a heating base plate with a groove for accommodating photovoltaic modules. A top cover is provided on the heating base plate, with its open end facing the heating base plate and having an upper pressure frame. Multiple horizontally arranged mounting brackets are provided inside the upper pressure frame, each mounting bracket having multiple sliding holes. Each sliding hole corresponds to at least one pressure sensor. A silicone plate is provided below the mounting brackets to seal the open end of the top cover. The pressure sensors abut against the silicone plate. The edge of the silicone plate is mounted on the upper pressure frame. An upper cavity for evacuation and inflation is formed between the silicone plate and the top cover. When the silicone plate abuts against the edge of the heating base plate, a lower cavity for evacuation and inflation is formed between the silicone plate and the heating base plate. It also includes an industrial control computer, which is electrically connected to multiple pressure sensors and is used to receive sensing data signals sent by multiple pressure sensors.

[0007] By adopting the above technical solution, when photovoltaic modules need to be laminated, the photovoltaic modules are laid flat on the heating base plate, and then the top cover is closed. After vacuuming the upper and lower cavities, air and volatiles between the photovoltaic module materials are removed. Then, the upper cavity is repeatedly inflated to create a pressure difference, thereby pressurizing the photovoltaic modules multiple times. The air pressure is used to laminate the silicone sheet onto the photovoltaic modules. Pressure sensors detect the pressure on the silicone sheet during the lamination process. By repeatedly pressurizing the upper cavity to a preset time, the occurrence of abnormalities in the photovoltaic modules is reduced. The pressure sensor measures the pressure on the silicone sheet, and the industrial control computer records the pressure status of the laminator according to the pressure detection location and detection time. The industrial control computer analyzes the pressure data of the silicone sheet at different locations to obtain pressure change curves at different locations, realizing the monitoring of the pressure status at different points of the laminator. This allows for timely and effective troubleshooting of abnormal photovoltaic modules.

[0008] Optionally, the upper cavity is provided with a plurality of moving components for moving the pressure sensor; the moving component includes a cylinder, the cylinder is electrically connected to the industrial control computer, the cylinder is vertically oriented toward the mounting bracket, the cylinder body is fixedly connected to the upper wall of the upper cavity, a first sliding block is fixedly connected to the piston rod of the cylinder, a plurality of connecting rods are hinged to the side wall of the first sliding block, and a second sliding block is hinged to the end of each connecting rod away from the first sliding block, the plurality of second sliding blocks correspond one-to-one with the plurality of sliding holes, and the second sliding blocks slide along the length of the sliding holes in the sliding holes, and the second sliding blocks located in the same sliding hole are detachably connected to the pressure sensor.

[0009] By employing the above technical solution, the pressure sensor is moved using a movable component, enabling it to detect pressure at different locations. This broadens the detection range for pressure points in the laminator. Furthermore, the pressure sensor can be moved according to the size of the photovoltaic modules, allowing for precise pressure detection at the same location relative to different sized modules during lamination. When the pressure sensor needs to be moved, the industrial control computer adjusts the relevant parameters of the cylinder. The piston rod of the cylinder moves, causing the first sliding block to move. This movement of the first sliding block, in turn, drives the connecting rod to push the second sliding block along the sliding hole. The movement of the second sliding block then moves the pressure sensor. Using a cylinder to move the pressure sensor ensures more precise positioning and achieves rapid and efficient movement.

[0010] Optionally, the movable component further includes a support rod, one end of which is fixedly connected to the upper wall of the upper cavity, and the other end of which is fixedly connected to the mounting bracket. The support rod has a sliding groove along its length, and the first sliding block is fixedly connected to a limiting block that slides along the sliding groove.

[0011] By adopting the above technical solution, when the hydraulic cylinder pushes the first sliding block, the limiting block slides along the sliding groove, reducing the possibility of the cylinder moving the first sliding block and causing circumferential rotation, thus making the movement of the first sliding block more stable.

[0012] Optionally, it also includes a camera and an alarm, both of which are electrically connected to the industrial control computer. The camera is used to capture the placement position of the photovoltaic modules and send position detection image information to the industrial control computer; the industrial control computer is used to receive the position detection image information and control the alarm to sound an alarm based on the position detection image information. The camera is also used to construct a three-dimensional shape based on the captured images of the photovoltaic modules' placement.

[0013] By adopting the above technical solution, the emission position of photovoltaic modules is detected by cameras. When the emission of photovoltaic modules is inaccurate, an alarm is triggered to remind the staff. The cameras are used to construct a three-dimensional shape of the photovoltaic module placement position, which makes it easier for staff to check the placement position of the photovoltaic modules and adjust the monitoring position of the pressure sensor according to the placement position.

[0014] Optionally, a high-temperature cloth is provided on the heating base plate, and a positioning reference line for positioning the photovoltaic module is provided on the high-temperature cloth.

[0015] By adopting the above technical solution, the photovoltaic modules are heated more evenly using high-temperature cloth. By setting positioning reference lines on the high-temperature cloth, the photovoltaic modules are placed with reference to the positioning reference lines, thereby making the placement of the photovoltaic modules more accurate.

[0016] Optionally, both the upper cavity sidewall and the lower cavity sidewall are provided with multiple vacuum sensors for detecting the cavity vacuum level, and all of the multiple vacuum sensors are connected to the industrial control computer.

[0017] By adopting the above technical solution, vacuum sensors are used to detect the vacuum level of the upper and lower cavities. The vacuum sensors send the detected vacuum level signal to the industrial control computer, which then plots the vacuum level change curve over time to monitor the vacuum level of the laminator. This facilitates troubleshooting of the laminator when lamination abnormalities occur in the components.

[0018] Secondly, this application provides a lamination monitoring method for a laminator with automatic pressure detection function as described in any one of the first aspects, employing the following technical solution: A lamination monitoring method, comprising: Multiple photovoltaic modules are laid flat on the heating base plate; Close the top cover of the laminator; use an air pump to evacuate both the upper and lower cavities; The upper cavity is pressurized multiple times to laminate the photovoltaic modules; after each pressurization, the pressure is maintained for a certain period of time. The pressure sensors measure the pressure data after pressurization and send the pressure data to the industrial control computer. The industrial control computer receives multiple pressure sensor data and inputs the pressure sensor data into a preset pressure monitoring model according to the pressure detection location and pressure detection time to obtain pressure change curves at different points.

[0019] By adopting the above technical solution, when photovoltaic modules need to be laminated, the photovoltaic modules are laid flat on the heating base plate, and then the top cover is closed. After vacuuming the upper and lower cavities, air and volatiles between the photovoltaic module materials are removed. Then, the upper cavity is repeatedly inflated to create a pressure difference, thereby pressurizing the photovoltaic modules multiple times. The air pressure is used to laminate the silicone sheet onto the photovoltaic modules. Pressure sensors detect the pressure on the silicone sheet during lamination. By repeatedly pressurizing the upper cavity to a preset time, the occurrence of abnormalities in the photovoltaic modules is reduced. The pressure sensor measures the pressure on the silicone sheet, and the industrial control computer analyzes the pressure data at different locations of the silicone sheet to obtain pressure change curves at different locations. This enables monitoring of the pressure status at different points of the laminator, thereby allowing for timely and effective troubleshooting of abnormal photovoltaic modules.

[0020] Optionally, before applying multiple pressurizations to the upper cavity, the method further includes: The industrial control computer adjusts the detection positions of multiple pressure sensors according to pressure detection requirements, so that the pressure sensors correspond to the photovoltaic modules, in order to detect the pressure change curves of different photovoltaic modules; the adjustment of the detection positions of multiple pressure sensors by the industrial control computer according to pressure detection requirements includes: The camera captures images of the photovoltaic modules placed on the high-temperature cloth, constructs a three-dimensional topography of the photovoltaic module distribution, and sends the three-dimensional topography of the photovoltaic module distribution to the industrial control computer. The industrial control computer pre-establishes the three-dimensional shape of the laminator, displays the three-dimensional shape of the photovoltaic module distribution, and calculates and displays the detection position of the pressure sensor in the three-dimensional shape of the laminator based on the parameters of the cylinder. The pressure detection location information to be detected is input based on the three-dimensional topography of the photovoltaic module distribution and the detection location of the pressure sensor; The industrial control computer acquires the pressure detection location information and adjusts the relevant parameters of the cylinder based on the pressure detection location information to move the pressure sensor.

[0021] By adopting the above technical solution, the three-dimensional shape of the photovoltaic modules on the high-temperature cloth is captured by a camera and displayed in the industrial control computer. The industrial control computer calculates and displays the pressure detection position of the pressure sensor based on the cylinder parameters, which makes it convenient for the staff to view the three-dimensional shape of the photovoltaic modules and the position of the pressure sensor. Furthermore, the position of the pressure sensor is adjusted according to the size and position of the photovoltaic modules and the position of the pressure sensor, so that the pressure sensor can detect the pressure at different positions, thus expanding the range of points for detecting the pressure of the laminator. Moreover, the position of the pressure sensor is moved according to the range of movement of the pressure sensor corresponding to different sizes of photovoltaic modules, so that when laminating photovoltaic modules of different sizes, the pressure of different sized photovoltaic modules relative to the same position of the photovoltaic modules is recorded.

[0022] Optionally, before inputting the pressure detection location information to be detected based on the three-dimensional topography of the photovoltaic module distribution and the detection location of the pressure sensor, the method further includes: The industrial control computer obtains the size and position information of the photovoltaic modules based on the three-dimensional shape of the photovoltaic module distribution; The industrial control computer determines whether the photovoltaic module is placed accurately based on the size and position information of the photovoltaic module. If the photovoltaic modules are not placed in the correct position, the industrial control computer will activate the alarm.

[0023] By adopting the above technical solution, cameras are used to detect the emission location of photovoltaic modules. When the emission of photovoltaic modules is inaccurate, an alarm is triggered to remind staff.

[0024] Optionally, the vacuum sensor sends vacuum data of the upper cavity and vacuum data of the lower cavity to the industrial control computer; The industrial control computer receives vacuum data from the upper cavity and vacuum data from the lower cavity, and inputs the vacuum data from the upper cavity and the lower cavity into a preset vacuum monitoring model according to the vacuum data detection time to obtain a vacuum data change curve; The pressure change curve is analyzed to determine if the photovoltaic module is under abnormal pressure. If the photovoltaic module is under abnormal pressure, the industrial control computer will activate the alarm. The vacuum data change curve of the upper cavity is analyzed to determine whether the vacuum state of the upper cavity is abnormal. If the vacuum state of the upper cavity is abnormal, the industrial control computer will control the alarm to sound. The vacuum data change curve of the lower cavity is analyzed to determine if the vacuum state of the lower cavity is abnormal. If the vacuum state of the lower cavity is abnormal, the industrial control computer will control the alarm to sound.

[0025] By adopting the above technical solution, the pressure change curve and vacuum change curve are analyzed by the preset pressure threshold range and vacuum threshold in each stage in the industrial control computer. When the pressure change curve or vacuum change curve does not meet the set standard, the industrial control computer controls the alarm to sound an alarm, so as to remind the staff to check the laminator.

[0026] In summary, this application includes at least one of the following beneficial technical effects: The industrial control computer records the pressure status of the laminator according to the pressure detection location and detection time, realizing the monitoring of the pressure status at different points of the laminator, thereby enabling timely and effective troubleshooting of abnormal photovoltaic modules.

[0027] By using a moving component to move the pressure sensor, the pressure sensor can detect pressure at different locations, thus expanding the range of points for detecting pressure in the laminator. Furthermore, the pressure sensor can be moved according to the different sizes of photovoltaic modules, corresponding to the range of positions on the pressure sensor. This allows for the detection of pressure relative to the same location on different sized photovoltaic modules during lamination. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the overall structure of a laminator with automatic pressure detection function according to an embodiment of this application.

[0029] Figure 2 This is a half-sectional schematic diagram of the overall structure of a laminator with automatic pressure detection function according to an embodiment of this application.

[0030] Figure 3 This is a schematic diagram highlighting the connection structure between the mounting bracket and the pressure sensor in an embodiment of this application.

[0031] Figure 4 This is a block diagram of the control structure of the industrial control computer in an embodiment of this application.

[0032] Figure 5 This is an exploded view highlighting the support rod and the first sliding block in the embodiments of this application.

[0033] Figure 6 This is a schematic flowchart of a lamination monitoring method according to an embodiment of this application.

[0034] In the diagram, 1. Heating base plate; 11. Photovoltaic module; 12. High-temperature cloth; 2. Top cover; 3. Upper pressure frame; 31. Sliding hole; 32. Mounting bracket; 4. Silicone plate; 41. Upper cavity; 42. Lower cavity; 5. Air pump; 6. Industrial computer; 61. Pressure sensor; 62. Vacuum sensor; 63. Camera; 64. Alarm; 7. Moving component; 71. Cylinder; 72. First sliding block; 721. Limiting block; 73. Connecting rod; 74. Second sliding block; 75. Support rod; 751. Sliding groove. Implementation

[0035] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0036] Furthermore, the term "and / or" in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. Additionally, the character " / " in this article, unless otherwise specified, generally indicates that the preceding and following related objects have an "or" relationship.

[0037] The embodiments of this application will now be described in further detail with reference to the accompanying drawings.

[0038] like Figure 1 and Figure 2 As shown, a laminator with automatic pressure detection function includes a heating base plate 1 with grooves. The grooves of the heating base plate 1 are used to place multiple photovoltaic modules 11. A top cover 2 is provided on the top of the heating base plate 1. The open end of the top cover 2 faces the heating base plate 1 and is fixedly connected to an upper pressure frame 3. The upper pressure frame 3 surrounds the top cover 2 and is opposite to the heating base plate 1. Multiple horizontally arranged "X"-shaped mounting brackets 32 are provided inside the upper pressure frame 3. Both the upper pressure frame 3 and the mounting brackets 32 are arranged parallel to the heating base plate 1. Figure 2 and Figure 3 As shown, the mounting bracket 32 ​​has multiple sliding holes 31 penetrating through it, and each sliding hole 31 contains at least one pressure sensor 61 for monitoring pressure changes. A silicone plate 4 seals the opening of the upper cover 2 below the mounting bracket 32, and the pressure sensor 61 abuts against the silicone plate 4. The edge of the silicone plate 4 is mounted on the upper pressure frame 3. The lower surface of the mounting bracket 32 ​​is higher than the lower surface of the upper pressure frame, creating a gap between the silicone plate 4 and the mounting bracket 32. Bolts are provided on the edge of the upper pressure frame 3, connecting the upper pressure frame 3 to the silicone plate 4 (not shown in the figure).

[0039] An upper cavity 41 is formed between the upper side of the silicone plate 4 and the upper cover 2; when the silicone plate 4 abuts against the edge of the heating base plate 1, a lower cavity 42 is formed between the lower part of the silicone plate 4 and the heating base plate 1. Both the upper cavity 41 and the lower cavity 42 are equipped with air pumps 5, which are used to perform vacuuming and inflation on the upper cavity 41 and the lower cavity 42.

[0040] like Figure 4 As shown, an industrial control computer 6 is also provided on one side of the laminator. The location of the industrial control computer 6 is not shown in the schematic diagram. The industrial control computer 6 is electrically connected to multiple pressure sensors 61. When the pressure sensor 61 detects the sensing data signal, the pressure sensor 61 sends the sensing data signal to the industrial control computer 6. The industrial control computer 6 receives the sensing data signals sent by multiple pressure sensors 61 to monitor the pressure status of the photovoltaic module 11 according to the pressure detection position.

[0041] When it is necessary to perform a lamination operation on the photovoltaic module 11, the photovoltaic module 11 is placed on the heating base plate 1 and heated by the heating base plate 1. The top cover 2 is then closed. The closing of the cover can be achieved by using a hydraulic or other lifting device to bring the silicone plate 4 into contact with the photovoltaic module 12, thereby sealing the groove of the heating base plate 1 with the silicone plate 4. Then, the air pump 5 located on the side wall of the lower cavity 42 and the air pump 5 located on the side wall of the upper cavity 41 are activated to perform a vacuuming operation on the lower cavity 42 and the upper cavity 41. After the vacuuming process of the lower cavity 42 and the upper cavity 41, the air pump 5 on the side wall of the upper cavity 41 is activated to inflate the upper cavity 41, thereby pressurizing the upper cavity 41, causing the silicone plate 4 to expand and laminate the photovoltaic module 11 located on the heating base plate 1. Since the pressure sensor 61 is used in such a way that one end of the pressure sensor 61 is fixed and the other end can freely expand and contract under pressure, the pressure sensor 61 is initially in contact with the silicone plate 4. When the silicone plate 4 presses down on the photovoltaic module 11, the pressure sensor 61 expands and contracts. During the lamination process of module 11, the thickness of photovoltaic module 11 decreases. This is because the purpose of lamination is primarily to eliminate air bubbles and increase the viscosity of EVA (the EVA in photovoltaic module 11 is typically around 0.5mm thick, exhibiting good fluidity at 140 degrees Celsius). Therefore, the thickness reduction of photovoltaic module 11 is negligible. This ensures that pressure sensor 61 remains in contact with silicone plate 4 during the extrusion process, preventing it from detaching. Thus, pressure sensor 61 remains in contact with silicone plate 3 throughout the lamination process, measuring the pressure change at each corresponding position of pressure sensor 61. Simultaneously, industrial control computer 6 analyzes the pressure data of photovoltaic module 11 during lamination based on the positions detected by pressure sensor 61. The analyzed pressure sensor data can then output information on abnormal photovoltaic modules 12, allowing operators to promptly and effectively detect abnormal pressure in the laminator and identify and address the abnormal photovoltaic modules 12, preventing quality issues due to delayed intervention.

[0042] Furthermore, in actual use, the silicone plate 4 may be damaged due to the expansion and contraction required during the lamination process. When the silicone plate 4 is damaged, since the silicone plate 4 and the upper pressure frame 3 are connected by bolts, the silicone plate 4 can be replaced simply by removing the bolts, which facilitates the operation of the staff.

[0043] By using pressure sensor 61 to detect the lamination process of photovoltaic module 11, staff can promptly identify abnormal pressure points in photovoltaic module 11 during the lamination process, and then resolve any abnormal lamination conditions in a timely manner.

[0044] Furthermore, such as Figure 2 As shown, a high-temperature cloth 12 is fixedly connected to the side of the heating base plate 1 near the silicone plate 4. The high-temperature cloth 12 also has positioning reference lines, which are not shown in the figure. When placing the photovoltaic module 11, it is placed on the high-temperature cloth 12. The high-temperature cloth 12 ensures more uniform heating of the photovoltaic module 11. By referring to the positioning reference lines when placing the photovoltaic module 11, the placement of the photovoltaic module 11 is more accurate. Figure 2 , Figure 3 and Figure 5 As shown, the upper cavity 41 is also equipped with a moving assembly 7 that drives multiple pressure sensors 61 to move and corresponds one-to-one with the mounting bracket 32. In this embodiment, the mounting bracket 32 ​​and the moving assembly 7 are arranged in four groups along the length of the upper pressure frame 3, and the pressure sensors 61 are arranged in four groups, with four pressure sensors 61 in each group. It should be noted that the number of pressure sensors 61 and the moving assembly 7 can be set according to the usage requirements of the laminator and is not limited to this. Furthermore, because the probe of the pressure sensor 61 is retractable, the pressure sensor 61 can move when it abuts against the silicone plate 4.

[0045] The pressure sensor 61 is moved by the moving component 7. On the one hand, the pressure sensor 61 can monitor the pressure at different locations. On the other hand, when the size of the photovoltaic module 11 changes, the pressure sensor 61 can adjust its position according to the different sizes of the photovoltaic module 11, thereby enabling accurate measurement of the pressure on the photovoltaic module 11.

[0046] The moving component 7 includes a cylinder 71 located inside the upper cavity 41. The cylinder 71 is electrically connected to the industrial control computer 6. The cylinder 71 is vertically oriented towards the mounting bracket 32. The cylinder body of the cylinder 71 is fixedly connected to the upper wall of the upper cavity 41. The piston rod of the cylinder 71 is fixedly connected to a first sliding block 72. Four connecting rods 73 are rotatably connected to the side wall of the first sliding block 72. The four connecting rods 73 are evenly distributed at the four corners of a rectangle on the side wall of the first sliding block 72. Each connecting rod 73 is rotatably connected to a second sliding block 74 at the end away from the first sliding block 72. Each sliding hole 31 and the corresponding connecting rod 73 are in the same vertical plane. All sliding holes 31 in the same group face the same point. Each sliding hole 31 corresponds to each second sliding block 74. The second sliding block 74 slides along the length of the hole in the sliding hole 31. Each pressure sensor 61 corresponds to a second sliding block 74. The pressure sensor 61 is detachably connected to the side of the second sliding block 74 near the silicone plate 4 by bolts. The bolts are not shown in the figure.

[0047] Of course, the number of connecting rods 73, second sliding blocks 74, and sliding holes 31 can be set according to the pressure position detection requirements of pressure sensors 61. Multiple pressure sensors 61 can also be installed in each sliding hole 31 (not shown in the figure). When two pressure sensors 61 are installed in each sliding hole 31, a second connecting rod can be fixedly connected to the side wall of the second sliding block 74 along the sliding hole 31. A third sliding block, which is slidably connected to the sliding hole 31, is fixedly connected to the second connecting rod. Another pressure sensor 61 can be detachably connected to the third sliding block. Similarly, three pressure sensors 61, four pressure sensors 61, etc., can be installed in the sliding hole. This application does not impose specific limitations on the embodiments.

[0048] When it is necessary to change the detection position of the pressure sensor 61, the cylinder 71 is activated. The cylinder 71 drives the first sliding block 72 to move. The first slider drives the four connecting rods 73 to move. The connecting rods 73 drive the second slider to move along the sliding hole 31. The second slider drives the pressure sensor 61 to move, thereby realizing the change of the detection position of the pressure sensor 61.

[0049] Furthermore, pressure sensor 61 may be damaged during repeated use. When pressure sensor 61 is damaged, it can be disassembled by loosening the bolts connecting pressure sensor 61 and the second moving block, thereby speeding up the work efficiency of staff when replacing pressure sensor 61.

[0050] Furthermore, such as Figure 5As shown, the moving assembly 7 also includes a support rod 75 located on one side of the cylinder 71. The support rod 75 is vertically arranged inside the upper cavity 41. One end of the support rod 75 is fixedly connected to the upper wall of the upper cavity 41, and the other end is fixedly connected to the upper surface of the mounting bracket 32. A limiting block 721 is fixedly connected to the side of the first sliding block 72 near the support rod 75. A sliding groove 751 is provided on the side of the support rod 75 near the cylinder 71, which is adapted to the limiting block 721 and allows the limiting block 721 to slide in the vertical direction.

[0051] When the cylinder 71 drives the first sliding block 72 to move up and down, the first sliding block 72 drives the limiting block 721 to move up and down along the sliding groove 751. The cooperation between the limiting block 721 and the sliding groove 751 makes the first sliding block 72 more stable during the movement, thereby reducing the phenomenon of position displacement of the first sliding block 72 during the movement.

[0052] like Figure 4 As shown, a camera 63 is also provided on one side of the laminator. The camera 63 is a binocular camera. The camera 63 is electrically connected to the industrial control computer 6. The industrial control computer 6 is also electrically connected to an alarm 64. When the industrial control computer 6 outputs abnormal photovoltaic module 12 through the pressure sensor data after data analysis, it will remind the staff that there is an abnormality in the photovoltaic module 11 by controlling the alarm 64.

[0053] Camera 63 is used to capture the placement position of photovoltaic module 11 and send position detection image information to industrial control computer 6. Industrial control computer 6 receives the position detection image information and controls alarm 64 to sound an alarm based on the position detection image information. When industrial control computer 6 determines that photovoltaic module 11 is in an abnormal position on heating base plate 1, industrial control computer 6 controls alarm 64 to open, thereby promptly reminding workers that the photovoltaic module 11 is not placed in an accurate position, reducing the occurrence of insufficient lamination process of photovoltaic module 11 due to abnormal placement. The structural diagrams of the laminator, camera 63, and alarm 64 are not shown.

[0054] Furthermore, the camera 63 is also used to construct a three-dimensional shape based on the captured images of the photovoltaic module 11's placement position. This allows staff to gain a more intuitive understanding of the photovoltaic module 11's placement position.

[0055] Furthermore, multiple vacuum sensors 62 are provided in both the upper cavity 41 and the lower cavity 42. The vacuum sensors 62 are electrically connected to the industrial control computer 6. The position and structure diagram of the vacuum sensors 62 is not shown.

[0056] When multiple air pumps 5 perform vacuuming operations on the upper cavity 41 and lower cavity 42, the vacuum degree of the upper cavity 41 and lower cavity 42 is monitored in real time by the vacuum sensor 62. The vacuum sensor 62 sends the detected vacuum data signal to the industrial control computer 6. The industrial control computer 6 receives the vacuum data signal and plots the vacuum degree monitoring curve of the laminator, so that the staff can monitor the status of the upper cavity and lower cavity of the laminator in real time.

[0057] Figure 6 A schematic flowchart of a lamination monitoring method according to an embodiment of the present disclosure is shown.

[0058] A lamination monitoring method is applied to the aforementioned laminator with automatic pressure detection function, such as... Figure 6 As shown, the lamination monitoring method includes the following steps (steps S101~S105): Step S101: Lay multiple photovoltaic modules 11 flat on the heating base plate 1; In this embodiment, multiple photovoltaic modules 11 are laid flat on the high-temperature cloth 12 of the heating base plate 1 according to the placement requirements of the photovoltaic modules 11. The photovoltaic modules 11 can be understood as modules used to laminate and form solar cells, such as glass, EVA, cells and backsheets.

[0059] Step S102: Close the upper cover 2 of the laminator; use a vacuum pump to evacuate both the upper cavity 41 and the lower cavity 42. Step S103: Pressurize the upper cavity 41 multiple times to laminate the photovoltaic module 11; maintain the pressure for a certain period of time after each pressurization. In this embodiment, by repeatedly pressurizing the upper cavity 41 and maintaining the pressure for a certain period of time after each pressurization, the possibility of bubbles forming in the laminate of the photovoltaic module 11 due to excessively rapid pressure rise during a single pressurization is reduced.

[0060] Specifically, the upper cavity 41 is pressurized for the first time using the air pump 5 to reach a first pressure and maintain that pressure for a first duration; the upper cavity 41 is pressurized for the second time using the air pump 5 to reach a second pressure and maintain that pressure for a second duration; the upper cavity 41 is pressurized for the third time using the air pump 5 to reach a third pressure and maintain that pressure for a third duration, and so on. In this embodiment, the number of pressurization cycles is determined based on the size of the module and the actual experiments of the photovoltaic module 11 during the pressurization process. The number of pressurization cycles is determined for different sizes of photovoltaic modules 11 based on different sizes of experiments. Finally, a more uniform pressurization pressure is determined for each size of photovoltaic module 11, further reducing the occurrence of bubbles and microcracks in the photovoltaic module 11 during the pressurization process.

[0061] Since different sizes of photovoltaic modules 11 need to be laminated or the pressure detection positions need to be changed when replacing the pressurized photovoltaic modules 11, the industrial control computer 6 needs to adjust the detection positions of multiple pressure sensors 61 according to the pressure detection requirements before the upper cavity 41 is pressurized multiple times. This ensures that the pressure sensors 61 correspond to the photovoltaic modules 11, so as to detect the pressure change curves of different photovoltaic modules 11. It should be noted that this application is only applicable to photovoltaic modules 11 of the same thickness but different sizes.

[0062] Specifically, the industrial control computer 6 adjusts the detection positions of the multiple pressure sensors 61 according to the pressure detection requirements, including (steps Sa~Sd) (not shown in the figure): Step Sa: The camera 63 captures images of the photovoltaic module 11 placed on the high-temperature cloth 12, constructs a three-dimensional shape of the distribution of the photovoltaic module 11, and sends the three-dimensional shape of the distribution of the photovoltaic module 11 to the industrial control computer 6. In step Sb, the industrial control computer 6 pre-establishes the three-dimensional shape of the laminator, displays the three-dimensional shape of the photovoltaic modules 11 distribution, and calculates and displays the detection position of the pressure sensor 61 in the three-dimensional shape of the laminator according to the parameters of the cylinder 71. Step Sc: Input the pressure detection location information to be detected based on the three-dimensional topography of the photovoltaic module 11 and the detection location of the pressure sensor 61; In this embodiment, before inputting the pressure detection location information based on the three-dimensional shape of the photovoltaic module 11 distribution and the detection location of the pressure sensor 61, the method further includes: the industrial control computer 6 acquiring the size and location information of the photovoltaic module 11 based on the three-dimensional shape of the photovoltaic module 11 distribution; the industrial control computer 6 determining whether the placement position of the photovoltaic module 11 is accurate based on the size and location information of the photovoltaic module 11; if the placement position of the photovoltaic module 11 is inaccurate, the industrial control computer 6 controlling the alarm 64 to sound an alarm. The camera 63 detects the emission position of the photovoltaic module 11, and when the emission of the photovoltaic module 11 is inaccurate, the alarm 64 sounds an alarm to alert the staff that the placement position of the photovoltaic module 11 is abnormal.

[0063] In step Sd, the industrial control computer 6 acquires the pressure detection position information and adjusts the relevant parameters of the cylinder 71 based on the pressure detection position information to move the pressure sensor 61.

[0064] In this embodiment, the camera 63 can be a binocular camera. The binocular camera acquires images of the 11 laminators of the photovoltaic module to obtain synchronously exposed images. Based on the two-dimensional image pixels of the images of the 11 laminators of the photovoltaic module, the third-dimensional depth information of the image is determined. Then, the three-dimensional shape of the photovoltaic module 11 is fused and stitched together based on the images, that is, the three-dimensional shape of the photovoltaic module 11 is constructed. The size and placement of the photovoltaic module 11 on each heating base plate 1 can be determined using the camera 63.

[0065] The photovoltaic module 11 on the high-temperature cloth 12 is photographed by camera 63 to construct a three-dimensional shape of the photovoltaic module 11 and displayed on the industrial control computer 6. The industrial control computer 6 calculates and displays the pressure detection position of pressure sensor 61 according to the parameters of cylinder 71, so that the staff can view the three-dimensional shape of photovoltaic module 11 and the position of pressure sensor 61. The position of pressure sensor 61 is adjusted according to the size and position of photovoltaic module 11 and the position of pressure sensor 61, so that pressure sensor 61 can detect pressure at different positions, and the range of points for detecting laminating machine pressure is wider. The position of pressure sensor 61 can be moved according to the size of different components, so that when laminating photovoltaic modules 11 of different sizes, the pressure of photovoltaic modules 11 of different sizes relative to the same position of photovoltaic module 11 is recorded.

[0066] In step S104, the pressure sensor 61 measures the pressure sensing data after pressurization and sends the pressure sensing data to the industrial control computer 6. In step S105, the industrial control computer 6 receives multiple pressure sensing data and inputs the pressure sensing data into a preset pressure monitoring model according to the pressure detection location and pressure detection time to obtain pressure change curves at different points.

[0067] In this embodiment of the application, the preset pressure monitoring model is a dynamic monitoring model of pressure curves set according to the pressure detection time, pressure detection point and the magnitude of the applied pressure.

[0068] The photovoltaic module 11 is pressurized multiple times, and the pressure is detected by the pressure sensor 61. The industrial control computer 6 receives the pressure sensing data sent by the pressure sensor 61, inputs the pressure sensing data into the preset pressure monitoring model, and outputs pressure change curves according to different pressurization pressures, different sensing data acquisition times, and different pressure detection locations. Based on the weight of the photovoltaic module 11 and the weight of the silicone plate 4, the industrial control computer 6 can obtain the pressure change curves of the photovoltaic module 11 under the silicone plate 4 at different pressure detection locations. Furthermore, a preset pressure threshold range corresponding to the pressure change curves is set using the pressure of the multiple pressurizations. If the detected pressure exceeds the preset pressure threshold range, the point and the abnormal value are highlighted. It should be noted that the data analysis is an existing technology in the relevant field. For example, data analysis can be performed on the historical variation range of pressure sensor 61 under normal pressure levels. For instance, a lamination experiment can be conducted on photovoltaic module 11, detecting the pressure range of multiple normal modules under laminator pressure, and setting a preset normal pressure threshold range based on the pressure range, thereby comparing and analyzing the detected pressure values. Alternatively, the pressure range of multiple abnormal modules under laminator pressure can be collected, and a preset abnormal pressure threshold range can be set based on the pressure range, thereby comparing and analyzing the detected pressure values. Alternatively, a pressure detection model can be established for analysis. The pressure detection model can be a neural network model trained from multiple sets of pressure data detected by the laminator based on historical level data.

[0069] The pressure change curve is used to record the pressure status at different points of the laminator and the pressure status at different pressurization intensities. Based on the pressure change curve and the corresponding preset pressure threshold range, it is analyzed whether the photovoltaic module 11 has abnormal pressure. If the pressure of the photovoltaic module 11 is abnormal, the industrial control computer 6 controls the alarm 64 to sound an alarm, so as to remind the staff to check the abnormal points inside the laminator in a timely and effective manner.

[0070] Furthermore, the system also includes: vacuum sensor 62 sending vacuum data of the upper cavity 41 and vacuum data of the lower cavity 42 to the industrial control computer 6; the industrial control computer 6 receiving the vacuum data of the upper cavity 41 and the lower cavity 42, inputting the vacuum data of the upper cavity 41 and the lower cavity 42 into a preset vacuum monitoring model according to the vacuum data detection time to obtain a vacuum data change curve; analyzing whether the vacuum state of the upper cavity 41 is abnormal based on the vacuum data change curve of the upper cavity 41, and if the vacuum state of the upper cavity 41 is abnormal, the industrial control computer 6 controls the alarm 64 to sound an alarm; analyzing whether the vacuum state of the lower cavity 42 is abnormal based on the vacuum data change curve of the lower cavity 42, and if the vacuum state of the lower cavity 42 is abnormal, the industrial control computer 6 controls the alarm 64 to sound an alarm.

[0071] By combining the vacuum data change curves of the upper cavity 41 and the lower cavity 42 with the pressure change curves at different points and pressures, the cause of the abnormality of the photovoltaic module 11 can be analyzed. This provides timely and effective reminders to staff that the laminated photovoltaic module 11 may experience abnormalities, facilitating timely handling of these issues.

[0072] This laminator with automatic pressure detection and lamination monitoring method reduces the likelihood of abnormalities in the photovoltaic module 11 by repeatedly pressurizing the upper cavity 41 to a preset duration. The pressure sensor 61 measures the pressure on the silicone plate 4, and the industrial control computer 6 analyzes the data to determine the pressure of the silicone plate 4 on the photovoltaic module 11 at that point. The industrial control computer 6 records the pressure status of the laminator according to the pressure detection location and detection time, realizing the monitoring of the pressure status at different points of the laminator and timely and effectively identifying abnormal points inside the laminator.

[0073] The terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0074] The above description is merely a preferred embodiment of this application and an explanation of the technical principles employed. Those skilled in the art should understand that the scope of this application is not limited to technical solutions formed by specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the foregoing application concept. For example, technical solutions formed by substituting the above features with (but not limited to) technical features with similar functions claimed in this application.

Claims

1. A laminator with automatic pressure detection function, characterized in that, The system includes a heating base plate (1) with a groove for accommodating a photovoltaic module (11). A top cover (2) is provided on the top of the heating base plate (1). The open end of the top cover (2) faces the heating base plate (1) and is equipped with an upper pressure frame (3). Multiple horizontally arranged mounting brackets (32) are provided inside the upper pressure frame. Multiple sliding holes (31) are provided on each mounting bracket (32), and each sliding hole (31) is equipped with at least one pressure sensor (61). Below the top cover (2), there is a silicone plate (4) that seals the opening of the top cover (2). The pressure sensors (61) are all in contact with the silicone plate (4). The edge of the silicone plate (4) is installed on the upper pressure frame (3). An upper cavity (41) for evacuation and inflation is formed between the silicone plate (4) and the top cover (2). When the silicone plate (4) is in contact with the edge of the heating base plate (1), a lower cavity (42) for evacuation and inflation is formed between the silicone plate (4) and the heating base plate (1). It also includes an industrial computer (6), which is electrically connected to multiple pressure sensors (61). The industrial computer (6) is used to receive sensing data signals sent by multiple pressure sensors (61). The upper cavity (41) is provided with a plurality of moving components (7) for moving the pressure sensor (61); the moving component (7) includes a cylinder (71), the cylinder (71) is electrically connected to the industrial control computer (6), the cylinder (71) is vertically facing the mounting bracket (32), the cylinder body of the cylinder (71) is fixedly connected to the upper wall of the upper cavity (41), and a first sliding block (72) is fixedly connected to the piston rod of the cylinder (71). Multiple connecting rods (73) are hinged to the side wall. Each connecting rod (73) is hinged to a second sliding block (74) at the end away from the first sliding block (72). The multiple second sliding blocks (74) correspond one-to-one with the multiple sliding holes (31). The second sliding block (74) slides along the length of the sliding hole (31) in the sliding hole (31). The second sliding block (74) located in the same sliding hole (31) and the pressure sensor (61) are detachably connected.

2. A laminator with automatic pressure detection function according to claim 1, characterized in that, The moving component (7) also includes a support rod (75), one end of which is fixedly connected to the upper wall of the upper cavity (41), and the other end of which is fixedly connected to the mounting bracket (32). The support rod (75) has a sliding groove (751) along its own length direction, and the first sliding block (72) is fixedly connected to a limiting block (721) that slides along the sliding groove (751).

3. A laminator with automatic pressure detection function according to claim 1 or 2, characterized in that, It also includes a camera (63) and an alarm (64), both of which are electrically connected to the industrial control computer (6). The camera (63) is used to capture the placement position of the photovoltaic module (11) and send the position detection image information to the industrial control computer (6). The industrial control computer (6) is used to receive the position detection image information and control the alarm (64) to sound an alarm based on the position detection image information. The camera (63) is also used to construct a three-dimensional shape based on the captured images of the placement of the photovoltaic module (11).

4. A laminator with automatic pressure detection function according to claim 3, characterized in that, A high-temperature cloth (12) is provided on the heating base plate (1), and a positioning reference line for positioning the photovoltaic module (11) is provided on the high-temperature cloth (12).

5. A laminator with automatic pressure detection function according to claim 4, characterized in that, Both the upper cavity (41) and the lower cavity (42) are equipped with multiple vacuum sensors (62) for detecting the vacuum level of the cavity, and the multiple vacuum sensors (62) are electrically connected to the industrial control computer (6).

6. A lamination monitoring method applied to a laminator with automatic pressure detection function as described in claim 5, characterized in that, include: Multiple photovoltaic modules (11) are laid flat on the heating base plate (1); Close the top cover (2) of the laminator; The upper cavity (41) and the lower cavity (42) are both evacuated using a vacuum pump. The upper cavity (41) was pressurized multiple times to laminate the photovoltaic module (11); the pressure was maintained for a certain period of time after each pressurization. The pressure sensor (61) measures the pressure sensing data after pressurization and sends the pressure sensing data to the industrial control computer (6). The industrial control computer (6) receives multiple pressure sensing data and inputs the pressure sensing data into a preset pressure monitoring model according to the pressure detection location and pressure detection time to obtain pressure change curves at different points.

7. The lamination monitoring method according to claim 6, further comprising, before the upper cavity (41) is pressurized multiple times: The industrial control computer (6) adjusts the detection positions of multiple pressure sensors (61) according to pressure detection requirements, so that the pressure sensors (61) correspond to the photovoltaic modules (11) to detect the pressure change curves of different photovoltaic modules (11); the industrial control computer (6) adjusts the detection positions of multiple pressure sensors (61) according to pressure detection requirements, including: The photovoltaic module (11) placed on the high-temperature cloth (12) is photographed by the camera (63), and a three-dimensional shape of the distribution of the photovoltaic module (11) is constructed. The three-dimensional shape of the distribution of the photovoltaic module (11) is sent to the industrial control computer (6). The industrial control computer (6) has a three-dimensional shape of the laminator pre-established, displays the three-dimensional shape of the photovoltaic module (11) distribution, and calculates the detection position of the pressure sensor (61) according to the parameters of the cylinder (71) and displays the three-dimensional shape of the laminator. The pressure detection location information to be detected is input based on the three-dimensional topography of the photovoltaic module (11) and the detection location of the pressure sensor (61); The industrial control computer (6) acquires the pressure detection position information and adjusts the relevant parameters of the cylinder (71) based on the pressure detection position information to move the pressure sensor (61).

8. The lamination monitoring method according to claim 7, characterized in that, Before inputting the pressure detection location information to be detected based on the three-dimensional topography of the photovoltaic module (11) and the detection location of the pressure sensor (61), the method further includes: The industrial control computer (6) obtains the size and position information of the photovoltaic module (11) based on the three-dimensional shape of the photovoltaic module (11) distribution; The industrial control computer (6) determines whether the placement of the photovoltaic module (11) is accurate based on the size and position information of the photovoltaic module (11); If the photovoltaic module (11) is not placed in the correct position, the industrial control computer (6) will control the alarm (64) to sound an alarm.

9. The lamination monitoring method according to claim 6, characterized in that, Also includes: The vacuum sensor (62) sends vacuum data of the upper cavity (41) and vacuum data of the lower cavity (42) to the industrial control computer (6); The industrial control computer (6) receives the vacuum data of the upper cavity (41) and the vacuum data of the lower cavity (42), and inputs the vacuum data of the upper cavity (41) and the vacuum data of the lower cavity (42) into the preset vacuum monitoring model according to the vacuum data detection time to obtain the vacuum data change curve; The pressure change curve is analyzed to determine whether the pressure on the photovoltaic module (11) is abnormal. If the pressure on the photovoltaic module (11) is abnormal, the industrial control computer (6) controls the alarm (64) to sound an alarm. Based on the vacuum data change curve of the upper cavity (41), analyze whether the vacuum state of the upper cavity (41) is abnormal. If the vacuum state of the upper cavity (41) is abnormal, the industrial control computer (6) controls the alarm (64) to alarm. Based on the vacuum data change curve of the lower cavity (42), analyze whether the vacuum state of the lower cavity (42) is abnormal. If the vacuum state of the lower cavity (42) is abnormal, the industrial control computer (6) controls the alarm (64) to alarm.

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