Stacking method, device and computer equipment, storage medium for photovoltaic assembly

Abstract

This application relates to a method, apparatus, computer device, and storage medium for stacking photovoltaic modules, comprising: determining the capacity status of a stack module to be replaced among multiple stack modules, each stack module being used to store photovoltaic modules to be processed in a corresponding processing module; and, in the event of an abnormal capacity status, swapping the positions of a target stack module that meets preset replacement conditions with the stack module to be replaced, wherein the target stack module includes any stack module other than the stack module to be replaced. This achieves the replacement of the stack module to be replaced with a target stack module in a normal state, ensuring that the stack module to be replaced is not affected by abnormal capacity status, thus guaranteeing balanced operation among processing modules and improving productivity and work efficiency.

Description

Technical Field

[0001] This application relates to the field of photovoltaic technology, and in particular to a method, apparatus, computer device, and storage medium for stacking photovoltaic modules. Background Technology

[0002] In the manufacturing process of photovoltaic modules, to maintain an equal production rhythm between upstream and downstream production lines, stacking equipment can be used to temporarily store excess capacity from the production lines, ensuring normal flow between them. However, when the stacking equipment is full, excess capacity on the corresponding production line cannot be stored, or when the stacking equipment is empty, an upstream anomaly will cause the downstream line to stop. Therefore, the capacity of the stacking equipment can easily affect the normal operation of the manufacturing process, leading to reduced capacity and work efficiency. Summary of the Invention

[0003] Therefore, it is necessary to provide a method, apparatus, computer equipment, and storage medium for stacking photovoltaic modules, addressing the problem that the capacity of stacking equipment in the prior art can easily affect the normal operation of the manufacturing process, leading to reduced production capacity and work efficiency.

[0004] To achieve the above objectives, this application provides a method for stacking photovoltaic modules, comprising:

[0005] Determine the capacity status of the stack module to be replaced among multiple stack modules, where each stack module is used to store the photovoltaic module to be processed in the corresponding processing module;

[0006] In the event that the capacity status is in an abnormal state, the target stack module that meets the preset replacement conditions will be swapped with the stack module to be replaced. The target stack module includes any stack module other than the stack module to be replaced among the plurality of stack modules.

[0007] In one embodiment, multiple processing modules are cascaded, and determining the capacity status of the stack module to be replaced among the multiple stack modules includes:

[0008] Obtain the first production quantity of the upstream processing module adjacent to the current processing module, and obtain the second production quantity of the downstream processing module adjacent to the current processing module, wherein the current processing module corresponds to the stack module to be replaced;

[0009] The capacity status of the stack module to be replaced is determined based on the first stack quantity of the stack module to be replaced and the comparison result between the first production quantity and the second production quantity.

[0010] In one embodiment, the abnormal state includes a full-load state, and determining the capacity state of the stack module to be replaced based on the first stack quantity of the stack module to be replaced and the comparison result between the first production quantity and the second production quantity includes:

[0011] When the first stack quantity of the stack module to be replaced is greater than or equal to a first preset value, and when the first production quantity is greater than the second production quantity, it is determined that the capacity status of the stack module to be replaced is in the full material state.

[0012] If the first stack quantity of the stack module to be replaced is greater than or equal to a first preset value, and the first production quantity is less than the second production quantity, it is determined that the capacity status of the stack module to be replaced is in a normal state.

[0013] In one embodiment, the abnormal state includes an idle state, and determining the capacity state of the stack module to be replaced based on the first stack quantity of the stack module to be replaced and the comparison result between the first production quantity and the second production quantity includes:

[0014] If the first stack quantity of the stack module to be replaced is less than or equal to the second preset value, and the first production quantity is greater than the second production quantity, it is determined that the capacity status of the stack module to be replaced is in a normal state.

[0015] If the first stack quantity of the stack module to be replaced is less than or equal to the second preset value, and the first production quantity is less than the second production quantity, it is determined that the capacity status of the stack module to be replaced is in the idle state.

[0016] In one embodiment, the step of swapping the target stack module that meets the preset replacement conditions with the stack module to be replaced when the capacity state is in an abnormal state includes:

[0017] Among multiple stack modules other than the stack module to be replaced, if the first state information of the candidate stack module is greater than the second state information of the remaining stack modules, the candidate stack module is determined as the target stack module.

[0018] Wherein, the first status information is the difference between the second stack number of the candidate stack module and the first stack number of the stack module to be replaced, and the second status information is the difference between the third stack number of the remaining stack modules and the first stack number of the stack module to be replaced.

[0019] In one embodiment, when there are multiple candidate stack modules, determining the candidate stack module as the target stack module when the first state information of the candidate stack module is greater than the second state information of the remaining stack modules (excluding the stack module to be replaced) includes:

[0020] If the comparison result between the third state information and the fourth state information of any candidate stack module meets the preset comparison conditions, the candidate stack module is determined as the target stack module.

[0021] Wherein, the third state information is the third production quantity of the upper-level processing module adjacent to the processing module corresponding to any candidate stack module, and the fourth state information is the fourth production quantity of the lower-level processing module adjacent to the processing module corresponding to any candidate stack module.

[0022] In one embodiment, the preset comparison condition includes: when the capacity state is at full capacity, the third state information is less than the fourth state information; and

[0023] When the capacity status is in an idle state, the third state information is greater than the fourth state information.

[0024] This application provides a stacking device for photovoltaic modules, comprising:

[0025] Multiple stack modules, each stack module being used to store photovoltaic modules to be processed by the corresponding processing module;

[0026] The determination module is used to determine the capacity status of the stack module to be replaced among multiple stack modules;

[0027] A moving module is used to swap the positions of a target stack module that meets preset replacement conditions with the stack module to be replaced when the capacity status is in an abnormal state. The target stack module includes any stack module other than the stack module to be replaced among the plurality of stack modules.

[0028] This application provides a computer device, including a memory and a processor, wherein the memory stores a computer program, and the processor executes the computer program to implement the steps of the method described above.

[0029] This application provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the steps of the method described above.

[0030] The aforementioned photovoltaic module stacking method, apparatus, computer equipment, and storage medium determine the capacity status of the stack module to be replaced. In the case of an abnormal capacity status, the target stack module that meets the preset replacement conditions is swapped with the stack module to be replaced. This allows the target stack module in a normal state to be used to replace the stack module to be replaced in an abnormal state, ensuring that the stack module to be replaced is not affected by the abnormal capacity status, thus guaranteeing the balance of operations among processing modules and improving production capacity and work efficiency. Attached Figure Description

[0031] To more clearly illustrate the technical solutions in the embodiments of this application or the conventional technology, the drawings used in the description of the embodiments or the conventional technology will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0032] Figure 1 This is one of the flowcharts illustrating a photovoltaic module stacking method provided in one embodiment;

[0033] Figure 2 This is a second flowchart illustrating a photovoltaic module stacking method provided in one embodiment;

[0034] Figure 3 This is a third flowchart illustrating a photovoltaic module stacking method provided in one embodiment;

[0035] Figure 4 This is a fourth flowchart illustrating a photovoltaic module stacking method provided in one embodiment;

[0036] Figure 5 This is one of the structural schematic diagrams of a photovoltaic module stacking device provided in one embodiment;

[0037] Figure 6 This is a second schematic diagram of the structure of a photovoltaic module stacking device provided in one embodiment.

[0038] Explanation of reference numerals in the attached figures:

[0039] Stack module: 100; Hook unit: 210; Track unit: 220. Detailed Implementation

[0040] To facilitate understanding of this application, a more complete description will be provided below with reference to the accompanying drawings, which illustrate embodiments of the present application. However, the present application can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that the disclosure of this application will be thorough and complete.

[0041] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains. The terms used in the specification of this application are for the purpose of describing specific embodiments only and are not intended to limit this application.

[0042] As used herein, the singular forms "a", "an" and "the" may also include the plural forms unless the context clearly dictates otherwise. It should also be understood that the terms "comprises / comprising" or "has / including" etc. specify the presence of the stated features, integers, steps, operations, components, parts or combinations thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, components, parts or combinations thereof. At the same time, in this specification, the term "and / or" includes any and all combinations of the related listed items.

[0043] In one embodiment, refer to Figure 1 , a stacking method for photovoltaic modules is provided, including step S102 and step S104.

[0044] Step S102: Determine the capacity status of the stack module to be replaced among multiple stack modules, and each of the stack modules is used to store the photovoltaic modules to be processed by the corresponding processing module.

[0045] Among them, a photovoltaic module, also known as a solar panel, is a device that converts light energy into electrical energy. It is composed of multiple solar cells, and by directly converting light into electronic energy, the utilization of solar energy is achieved, which helps to reduce the dependence on traditional energy sources such as fossil fuels and promotes sustainable development.

[0046] Furthermore, the manufacturing process of photovoltaic modules involves multiple processes, and each process usually requires a corresponding processing module to complete. The processing module can be understood as the pipeline equipment supporting the process. For the convenience of description and understanding, the "production line" or "production line" hereinafter refers to the processing module in this embodiment. The above-mentioned multiple processes include, for example, glass loading, film laying, string welding, layout, stack welding, second film, backplane, stack return, electroluminescence (EL) test, lamination, edge trimming, framing, welding junction box, curing, cleaning, current-voltage (IV) characteristic detection, final inspection, packaging and other processes. Each process has its specific requirements and procedures, and often requires a corresponding pipeline or equipment to support and automate the production process to improve efficiency and quality.

[0047] Production line balancing is a method and technique in assembly line production. By adjusting the workload or quantity of each process or workstation, the operation time of each process is made similar or equal to maximize production efficiency. In photovoltaic module manufacturing, if the operation time of upstream and downstream processes or workstations is uneven, or if an anomaly causes an imbalance in the production line, a stacking method can be used to solve the problem. A stack is a device used to store excess capacity on the production line. When the capacity of the upstream process is greater than that of the downstream process, the excess capacity cannot be immediately consumed, so it can be temporarily stored in the stack to maintain the normal flow of the production line. This avoids the accumulation of modules on the lower-capacity production line, which affects production efficiency. Conversely, when the capacity of the upstream process is less than that of the downstream process, the temporarily stored capacity in the stack can be consumed, avoiding capacity waste and improving production efficiency and capacity utilization. The aforementioned capacity can be understood as the number of modules produced by the production line.

[0048] However, in related technologies, the number of components that a stack can store is limited. When the stack is full of components, if the production line experiences an imbalance (i.e., inconsistent upstream and downstream capacity), the excess capacity cannot be stored, leading to wasted capacity. To store the excess capacity, the number of stacks needs to be increased to expand the stack capacity, but this increases production costs. Furthermore, when the stack is empty, if the upstream production line experiences a material shortage, and there is no inventory in the stack to replenish the shortage, the downstream production line will stop operating, affecting the entire production line's cycle time and reducing capacity and efficiency. Therefore, this embodiment provides a method for stacking photovoltaic modules to overcome these shortcomings.

[0049] In this system, multiple processing modules (also known as production lines, assembly lines, or assembly lines) can be set up when processing the same type of work order or material. Each processing module corresponds to a stack module to store the photovoltaic modules to be processed by that module. This stack module can be understood as storing excess capacity from the upstream production line that the current processing module cannot absorb. The capacity of the stack module can be understood as the actual number of photovoltaic modules stored in it. The capacity status of the stack module can be divided into normal and abnormal states. An abnormal capacity status of the stack module can include the following operating conditions:

[0050] The first operating condition is that the stack module is in a full-load state: Let's denote the processing module corresponding to a certain stack module as line A for explanation. When the number of photovoltaic modules contained in the stack module of line A reaches a first preset value, which can be slightly less than or equal to the maximum capacity of the stack module, the stack module can be considered to be internally filled with modules. Simultaneously, the capacity comparison between the upstream and downstream processing modules of line A can be used to comprehensively determine whether the stack module of line A is in a full-load state. Here, capacity refers to the number of modules produced by the processing module. That is, when the capacity of the upstream processing module of line A is greater than the capacity of the downstream processing module, the upstream processing module will transfer more capacity to line A. This means that the stack module corresponding to line A needs to store more photovoltaic modules to maintain production balance among the processing modules. However, the stack module of line A is already full of modules and cannot accommodate more. Therefore, at this time, the stack module corresponding to line A is in a full-load state, meaning that line A faces the risk of material blockage.

[0051] The second operating condition is that the stack module is in an idle state: Let's denote the processing module corresponding to a certain stack module as Line A for explanation. When the number of photovoltaic modules contained in the stack module of Line A is less than or equal to a second preset value, which can be slightly less than or equal to the minimum capacity value of the stack module, then the stack module can be regarded as having no photovoltaic modules stored inside. At the same time, the capacity comparison between the upstream and downstream processing modules of Line A can be combined to comprehensively determine whether the stack module of Line A is in an idle state. That is, when the capacity of the upstream processing module of Line A is less than the capacity of the downstream processing module of Line A, the upstream processing module of Line A cannot transfer normal capacity to Line A for processing. However, the current inventory of the stack module corresponding to Line A is zero or close to zero, so the stack module corresponding to Line A cannot supplement the capacity of Line A. This will lead to the shutdown of Line A and its downstream processing modules. Therefore, at this time, the stack module corresponding to Line A is in an idle state, that is, Line A is at risk of material shortage.

[0052] As mentioned above, the following operating conditions can be included when the capacity status of the stack module is in a normal state:

[0053] The first operating condition is that the number of photovoltaic modules contained in the stacking module of line A reaches the first preset value. The stacking module can be regarded as being filled with modules. Moreover, the capacity of the upstream processing module of line A is less than the capacity of the downstream processing module of line A. At this time, the stacking module corresponding to line A is in normal condition and can consume the inventory of line A to supplement the capacity of line A. That is, there is no risk of material blockage in line A.

[0054] The second operating condition is that the number of photovoltaic modules contained in the stack module of line A is less than or equal to the second preset value. The stack module can be regarded as not storing photovoltaic modules inside, and the production capacity of the upstream processing module of line A is greater than the production capacity of the downstream processing module of line A. At this time, the stack module corresponding to line A is in normal state and can normally store the excess production capacity transmitted from the upstream processing module of line A. That is, there is no risk of material shortage for line A.

[0055] This allows us to determine whether the capacity status of the stack module to be replaced is in a normal or abnormal state. Based on the capacity status of the stack module to be replaced, we can then decide whether to swap the target stack module with the stack module to be replaced if the capacity status is normal, thereby preventing the stack module to be replaced if it is in an abnormal state from affecting the normal operation of the production line.

[0056] Step S104: When the capacity status is in an abnormal state, the target stack module that meets the preset replacement conditions is swapped with the stack module to be replaced. The target stack module includes any stack module other than the stack module to be replaced from a plurality of stack modules.

[0057] Specifically, when the capacity of the stack module to be replaced is in an abnormal state, a target stack module that meets the preset replacement conditions needs to be retrieved and swapped with the stack module to be replaced. This ensures that the processing module corresponding to the stack module to be replaced will not be affected by material blockage or interruption, thus maintaining production cycle and capacity. In other words, if the capacity is full, indicating a risk of material blockage in the processing module corresponding to the stack module to be replaced, a stack module with an actual internal storage quantity close to zero can be used as the target stack module. This target stack module is then swapped with the stack module to be replaced, allowing the target stack module to continue accommodating excess components accumulated in the processing module. It should be noted that, in addition to being based on the actual internal storage quantity of each stack module, the preset replacement condition can also be based on the comparison of the actual internal storage quantity of each stack module with the production capacity of the upstream and downstream processing modules of each stack module. For example, if there are at least two stack modules with the same actual internal storage quantity, any stack module can be directly selected as the target stack module. Alternatively, the production capacity of the upstream and downstream processing modules of each stack module can be compared. For example, if, among the at least two stack modules with the same actual internal storage quantity, there is a stack module whose upstream processing module has a smaller output quantity than its downstream processing module, then that stack module can be selected as the target stack module.

[0058] On the other hand, when the capacity is idle, it indicates that the processing module corresponding to the stack module to be replaced is at risk of running out of materials. In this case, a stack module with an internal storage quantity close to its maximum capacity can be selected as the target stack module, and its position can be swapped with the stack module to be replaced. This allows the target stack module to replenish photovoltaic modules to the processing module at risk of running out of materials, maintaining smooth operation between production lines. It should be noted that when at least two stack modules have the same internal actual storage quantity, either stack module can be directly selected as the target stack module, or the production capacity of the processing modules before and after each stack module can be compared. For example, among the at least two stack modules with the same internal actual storage quantity, if the output quantity of the upstream processing module corresponding to one stack module is greater than the output quantity of the downstream processing module, then that stack module can be selected as the target stack module.

[0059] Therefore, by swapping the positions of the stack module to be replaced that is in an abnormal capacity state with the target stack module that meets the preset replacement conditions, multiple processing modules can assist each other to ensure that the processing module corresponding to the stack module to be replaced will not be affected by material blockage or material shortage, thus ensuring that the production cycle and capacity are not affected.

[0060] Alternatively, the transportation of each stack module can be achieved using a crane. For example, each stack module can have a built-in mesh cage to store the production capacity that the corresponding processing module cannot process. The top of the built-in mesh cage is equipped with a retaining ring or magnetic block to connect with the hook or magnetic block of the crane, so that the stack module to be replaced and the target stack module can be lifted by the crane to exchange their positions. Another method of transportation is to lay stack movement tracks on the ground and control the movement of the stack module to be replaced and the target stack module on the ground tracks to exchange their positions. Furthermore, each processing module can be set up as an aerial assembly line, allowing the photovoltaic modules to flow on the aerial assembly line, thereby directly moving the modules to replace the stack modules to be replaced and the target stack module.

[0061] Optionally, the stack module to be replaced can be a stack module that actively initiates an alarm, or a stack module determined according to human needs. In other embodiments, for example, when the stack module to be replaced is full or has no stored components, it will actively initiate an alarm signal to the Manufacturing Execution System (MES) and send a position swap request to swap positions with other stack modules. At the same time, the monitoring module (Standards for Supervisory Control and Data Acquisition, SCADA) comprehensively determines whether the stack module to be replaced is in an abnormal state based on the actual storage quantity of the module to be replaced and the capacity comparison between the upstream and downstream processing modules of the module to be replaced. If the capacity status of the module to be replaced is abnormal, the MES system synchronously monitors the number of components in the stack modules corresponding to each processing module under the same work order or the same material, and / or the capacity comparison between the upstream and downstream of each processing module, to determine the target stack module that meets the preset replacement conditions. Here, the SCADA module is a software module used to monitor and control industrial processes. It is typically used to monitor and operate remote equipment, monitor real-time data, and perform remote control. The MES system is used to monitor and manage the manufacturing process, collect, analyze and display production data in real time, support the execution and management of production plans, and provide the ability to track and trace the production process.

[0062] The photovoltaic module stacking method provided in this embodiment determines the capacity status of the stacking module to be replaced. When the capacity status is abnormal, the target stacking module that meets the preset replacement conditions is swapped with the stacking module to be replaced. This allows the target stacking module in a normal state to replace the stacking module to be replaced in an abnormal state, ensuring that the stacking module to be replaced is not affected by the abnormal capacity status, thus guaranteeing the balance of operations among processing modules and improving production capacity and work efficiency.

[0063] In one embodiment, such as Figure 2 As shown, multiple processing modules are cascaded. Step S102 determines the capacity status of the stack module to be replaced among the multiple stack modules, including steps S202 and S204.

[0064] Step S202: Obtain the first production quantity of the upstream processing module adjacent to the current processing module, and obtain the second production quantity of the downstream processing module adjacent to the current processing module. The current processing module corresponds to the stack module to be replaced.

[0065] The replacement stack module is used to store excess capacity that the current processing module has not been able to process in time. The first production quantity and the second production quantity can both be understood as the number of components produced by the corresponding processing module during operation (i.e., the "capacity" mentioned above). It is understood that when the number of stacks inside the replacement stack module is greater than or equal to the first preset value, it indicates that the number of photovoltaic modules stored inside the current replacement stack module has reached the maximum capacity of the equipment. The replacement stack module sends an alarm signal and a request to change its position to the MES system. Conversely, when the number of stacks inside the replacement stack module is less than or equal to the second preset value, it indicates that the current replacement stack module does not store any photovoltaic modules, and the replacement stack module also sends an alarm signal and a request to change its position to the MES system.

[0066] Furthermore, upon receiving alarm and request signals from the stack module to be replaced, the MES system's backend will retrieve and monitor stack modules belonging to the same work order or material type as the stack module to be replaced. Simultaneously, the SCADA module will measure the flow rate of components before and after the processing module corresponding to the stack module to be replaced, thereby verifying the alarm signal initiated by the stack module to be replaced. That is, when the stack module to be replaced issues an alarm signal indicating that its currently stored components have reached maximum capacity, the comparison of production quantities between adjacent processing modules can be used to verify whether the stack module to be replaced is in an abnormal state (full state). Similarly, when the stack module to be replaced issues an alarm signal indicating that it currently has no stored components, the comparison of production quantities between adjacent processing modules can be used to verify whether the stack module to be replaced is in an abnormal state (idle state).

[0067] Step S204: Determine the capacity status of the stack module to be replaced based on the first stack quantity and the comparison between the first production quantity and the second production quantity.

[0068] The first stack quantity can be understood as the actual number of components stored inside the stack module to be replaced. When the first stack quantity of the stack module to be replaced reaches the standard of the maximum capacity of the equipment, the stack module to be replaced can initiate an alarm signal and a signal to request a change of position. Then the SCADA module measures the production quantity of the processing modules before and after the current processing module position. If the first production quantity of the upper-level processing module is greater than the second production quantity of the lower-level processing module, it indicates that the capacity status of the stack module to be replaced is in an abnormal state (full material state). However, if the second production quantity of the upper-level processing module is less than the second production quantity of the lower-level processing module, it indicates that the capacity status of the stack module to be replaced is in a normal state, and the system will reject the request of the stack module to be replaced.

[0069] When the number of the first stack of the stack module to be replaced reaches the minimum capacity standard of the device (at this time, it can be assumed that there are no components stored inside the stack module to be replaced), the stack module to be replaced can initiate an alarm signal and a signal to request a change of position. Similarly, the SCADA module will measure the production quantity of the processing modules before and after the current processing module position. If the first production quantity of the upper-level processing module is greater than the second production quantity of the lower-level processing module, it means that the capacity status of the stack module to be replaced is in a normal state, and the system will reject the request of the stack module to be replaced. However, if the second production quantity of the upper-level processing module is less than the second production quantity of the lower-level processing module, it means that the capacity status of the stack module to be replaced is in an abnormal state (idle state).

[0070] By combining the comparison of the production quantity between processing modules before and after the current processing module position, the capacity status represented by the first stack quantity of the stack module to be replaced is verified a second time, thereby improving the accuracy and effectiveness of obtaining the capacity status and making the replacement efficiency between stack modules more efficient.

[0071] In one embodiment, such as Figure 3 As shown, abnormal states include full material state. Step S204 determines the capacity state of the stack module to be replaced based on the first stack quantity of the stack module to be replaced and the comparison result between the first production quantity and the second production quantity, including steps S302 and S304.

[0072] Step S302: When the first stack quantity of the stack module to be replaced is greater than or equal to the first preset value, and the first production quantity is greater than the second production quantity, it is determined that the capacity status of the stack module to be replaced is in a full-material state.

[0073] The "full-load" state can be understood as the first stack quantity within the module to be replaced reaching the maximum capacity of the equipment, and the current processing module facing a risk of material blockage. Specifically, when the first stack quantity of the module to be replaced is greater than or equal to a first preset value (which can be slightly less than or equal to the maximum capacity of the module to be replaced), and the first production quantity of the upstream processing module adjacent to the current processing module is greater than the second production quantity of the downstream processing module, it indicates that more capacity will be supplied upstream of the current processing module. This means the module to be replaced needs to store more photovoltaic modules to maintain production balance among the processing modules. However, since the first stack quantity of the module to be replaced has reached its maximum capacity, it cannot accommodate more capacity. Therefore, the capacity state of the module to be replaced is determined to be full, and the corresponding current processing module faces a risk of material blockage.

[0074] Step S304: When the first stack quantity of the stack module to be replaced is greater than or equal to the first preset value, and the first production quantity is less than the second production quantity, it is determined that the capacity status of the stack module to be replaced is in a normal state.

[0075] In cases where the number of the first stack of the stack module to be replaced is greater than or equal to the first preset value, although the number of the first stack of the stack module to be replaced reaches the maximum capacity standard of the equipment, the first production quantity of the adjacent upper-level processing module is less than the second production quantity of the adjacent lower-level processing module. This indicates that the upstream of the current processing module cannot continuously transmit normal production capacity to the current processing module for processing. At this time, the components stored inside the stack module to be replaced can be consumed to supplement the production capacity of the current stack module. Therefore, it can be determined that the capacity status of the stack module to be replaced is in a normal state, and there is no risk of material blockage in the current processing module corresponding to the stack module to be replaced.

[0076] In one embodiment, such as Figure 4 As shown, the abnormal state includes the idle state. Step S204 determines the capacity state of the stack module to be replaced based on the first stack quantity of the stack module to be replaced and the comparison result between the first production quantity and the second production quantity, including steps S402 and S404.

[0077] Step S402: When the first stack quantity of the stack module to be replaced is less than or equal to the second preset value, and the first production quantity is greater than the second production quantity, it is determined that the capacity status of the stack module to be replaced is in a normal state.

[0078] In cases where the first stack quantity of the stack module to be replaced is less than or equal to the second preset value, although the first production quantity of the adjacent upper-level processing module is greater than the second production quantity of the adjacent lower-level processing module, the first stack quantity of the stack module to be replaced reaches the minimum capacity standard of the equipment. The stack module to be replaced has sufficient storage space to store the excess capacity transmitted from the upstream processing module. Therefore, the capacity status of the stack module to be replaced is in a normal state, and there is no risk of material shortage in the processing module corresponding to the stack module to be replaced.

[0079] Step S404: When the first stack quantity of the stack module to be replaced is less than or equal to the second preset value, and the first production quantity is less than the second production quantity, it is determined that the capacity status of the stack module to be replaced is in an idle state.

[0080] In this context, the idle state can be understood as the first stack quantity within the stack module to be replaced reaching the minimum capacity of the equipment, and the current processing module facing a material shortage risk. Specifically, if the first stack quantity of the stack module to be replaced is less than or equal to a second preset value (which can be slightly less than or equal to the minimum capacity of the stack module to be replaced), and the first production quantity of the upstream processing module adjacent to the current processing module is less than the second production quantity of the downstream processing module adjacent to the current processing module, it indicates that the upstream of the current processing module cannot continuously supply normal production capacity for processing. However, if the current inventory of the stack module to be replaced is zero or close to zero, then the stack module to be replaced cannot replenish the production capacity of the current processing module. This will lead to a shutdown of the current processing module and its downstream components, resulting in the stack module to be replaced and its capacity being unusable. In this case, the capacity status of the stack module to be replaced is idle, and the corresponding current processing module faces a material shortage risk.

[0081] In one embodiment, step S104 involves swapping the positions of the target stack module that meets the preset replacement conditions with the stack module to be replaced when the capacity status is in an abnormal state, including step S502.

[0082] Step S502: Among the multiple stack modules other than the stack module to be replaced, if the first state information of the candidate stack module is greater than the second state information of the remaining stack modules, the candidate stack module is determined as the target stack module.

[0083] The first state information is the difference between the second stack number of the candidate stack modules and the first stack number of the stack modules to be replaced, and the second state information is the difference between the third stack number of the remaining stack modules and the first stack number of the stack modules to be replaced.

[0084] The third stack number of the remaining stack module may include the maximum stack number or the minimum stack number in the remaining stack module.

[0085] When the stack module to be replaced is at full capacity, the MES system queries and monitors multiple stack modules corresponding to other processing modules of the same type of work order or material as the current processing module. The stack module with the smallest number of internal storage components (i.e., stack count) becomes the candidate stack module. The third stack count of the remaining stack modules refers to the smallest stack count among the remaining stack modules. That is, the second stack count of the candidate stack module is less than the smallest stack count among the remaining stack modules. At this point, the difference between the second stack count of the candidate stack module and the first stack count of the stack module to be replaced is greater than the difference between the smallest stack count and the first stack count among the remaining stack modules. Therefore, the candidate stack module with the smallest stack count is selected as the optimal target stack module and swapped with the stack module to be replaced. The target stack module has sufficient storage space to store the excess capacity from the upstream of the current processing module, effectively maintaining production balance and cycle time among the processing modules.

[0086] When the capacity of the stack module to be replaced is idle, the MES system similarly queries and monitors multiple stack modules corresponding to other processing modules that belong to the same work order or the same material as the current processing module. The stack module with the largest number of internal storage components (i.e., stack count) becomes the candidate stack module. The third stack count of the remaining stack modules refers to the largest stack count among the remaining stack modules. That is, the second stack count of the candidate stack module is greater than the largest stack count among the remaining stack modules. At this point, the difference between the second stack count of the candidate stack module and the first stack count of the stack module to be replaced is greater than the difference between the largest stack count and the first stack count among the remaining stack modules. Therefore, the candidate stack module with the largest stack count is selected as the optimal target stack module and swapped with the stack module to be replaced. The target stack module then has sufficient stack components to supplement the capacity of the current processing module, preventing downtime and ensuring production balance and cycle time among the processing modules.

[0087] In one embodiment, when there are multiple candidate stack modules, step S502 determines the candidate stack module as the target stack module when the first state information of the candidate stack module is greater than the second state information of the remaining stack modules among the multiple stack modules other than the stack module to be replaced. This includes the following steps: if the comparison result between the third state information and the fourth state information of any candidate stack module meets the preset comparison conditions, any candidate stack module is determined as the target stack module.

[0088] The third state information is the third production quantity of the processing module above the processing module corresponding to any candidate stack module, and the fourth state information is the fourth production quantity of the processing module below the processing module corresponding to any candidate stack module.

[0089] When there are multiple candidate stack modules, that is, when the number of second stacks of multiple candidate stack modules is equal, the MES system will also monitor the production quantity of the front and rear processing modules corresponding to the processing modules of multiple candidate stack modules.

[0090] When the capacity of the stack module to be replaced is full, the corresponding current processing module is at risk of material blockage. If there are multiple candidate stack modules with the same and smallest number of second stacks, the MES system will compare the upstream and downstream flow rates of the processing modules corresponding to the multiple candidate stack modules. For example, if the upstream production quantity of the processing module corresponding to the first stack module is greater than the downstream production quantity, the system will continue to compare the processing module corresponding to the second stack module. If the third production quantity of the upper level of any candidate stack module is less than the fourth production quantity of the lower level, it means that the candidate stack module not only has the smallest stack quantity, but its corresponding processing module is also at risk of material shortage. Therefore, the candidate stack module is used as the target stack module and swapped with the stack module to be replaced. After the swap, the stack module to be replaced with sufficient internal components can supplement the capacity of the processing module at risk of material shortage, while the candidate stack module without internal components can store the excess capacity of the current processing module at risk of material blockage.

[0091] When the capacity of the stack module to be replaced is idle, the corresponding current processing module is at risk of material shortage. If there are multiple candidate stack modules with the same and largest number of second stacks, the MES system will compare the upstream and downstream flow rates of the processing modules corresponding to the multiple candidate stack modules. For example, if the upstream production quantity of the processing module corresponding to the first stack module is less than the downstream production quantity, the system will continue to compare the processing module corresponding to the second stack module. If the third production quantity of the upper level of any candidate stack module is greater than the fourth production quantity of the lower level, it means that the candidate stack module not only has the largest number of stacks, but also that the corresponding processing module is at risk of material blockage. Therefore, the candidate stack module is used as the target stack module and swapped with the stack module to be replaced. After the swap, the stack module to be replaced that does not store components can store the excess capacity of the processing module at risk of material blockage, while the candidate stack module that is full of components can supplement the capacity of the current processing module at risk of material shortage.

[0092] In one embodiment, the preset comparison conditions include: when the capacity is in a full state, the third state information is less than the fourth state information, and when the capacity is in an idle state, the third state information is greater than the fourth state information.

[0093] When the capacity of the stack module to be replaced is full, the current processing module corresponding to the stack module to be replaced faces the risk of material blockage. In this case, among multiple candidate stack modules with the same and smallest stack quantity, the candidate stack module whose third production quantity of the adjacent upper-level processing module is less than the fourth production quantity of the adjacent lower-level processing module should be selected as the target stack module. Thus, the target stack module with sufficient storage space can store the excess capacity of the processing module with the risk of material blockage, while the stack module to be replaced with sufficient internal storage can supplement the capacity of the processing module with the risk of material shortage.

[0094] When the capacity of the stack module to be replaced is idle, the current processing module corresponding to the stack module to be replaced faces the risk of material shortage. In this case, among multiple candidate stack modules with the same and largest stack quantity, the candidate stack module whose third production quantity of the adjacent upper-level processing module is greater than the fourth production quantity of the adjacent lower-level processing module should be selected as the target stack module. Thus, the target stack module with sufficient internal storage can supplement the production capacity of the processing module with the risk of material shortage, while the stack module to be replaced with sufficient storage space can store the excess production capacity of the processing module with the risk of material blockage.

[0095] Based on this, when selecting target stack modules, the target stack modules corresponding to different abnormal states are obtained by considering the number of stacks in each stack module and the production quantity of processing modules before and after each stack module position. These target stack modules are then swapped with the stack modules to be replaced. After the position swap, the stack module to be replaced can meet the production line cycle time of the processing module corresponding to the target stack module, while the target stack module can meet the production line cycle time of the current processing module corresponding to the stack module to be replaced. This not only ensures that the production cycle time and capacity of each processing module are not affected by material blockage or material shortage, but also allows stack modules corresponding to processing modules with the same work order or the same material to cooperate with each other, achieving a win-win situation.

[0096] In one embodiment, a photovoltaic module stacking device is provided, comprising: a plurality of stacking modules, a determining module, and a moving module.

[0097] Each stack module is used to store the photovoltaic modules to be processed by the corresponding processing module. The determining module is used to determine the capacity status of the stack module to be replaced among multiple stack modules. The moving module is used to swap the target stack module that meets the preset replacement conditions with the stack module to be replaced when the capacity status is abnormal. The target stack module includes any stack module other than the stack module to be replaced among multiple stack modules.

[0098] The working principle of each module can be found in the relevant descriptions of the corresponding step embodiments, and will not be repeated here.

[0099] The structural device of the mobile module can be implemented using a crane; see reference for details. Figure 5 and Figure 6 The moving module may include a hook unit 210 and a track unit 220. The hook unit 210 may include an electric hoist and a suspension component connected to the electric hoist. The track unit 220 may include a track and supports on both sides. The electric hoist may consist of a motor, gearbox, brake, and pulleys. The electric hoist is driven by the motor, which drives the gearbox to work, and the object is raised, lowered, or moved laterally through gear transmission. The suspension component is a loading tool connected to the electric hoist. It is used to suspend and fix the stack module 100. It can be fixed above the stack module 100, and the lifting or moving function of the electric hoist enables the stack module 100 to be lifted, suspended, and moved on the track unit 220.

[0100] The suspension component can be a hook or a magnetic block. The structure within the stack module 100 may include a processing module, a lifting device, an outer protective fence, and an internal container cage. The internal container cage is used to store components that the processing module cannot process in a timely manner. The top of the internal container cage can be fitted with a retaining ring or a magnetic block for connection with the hook or magnetic block of the suspension component. Thus, when the stack module 100 to be replaced needs to be swapped with the target stack module 100, the internal container cages of both the stack module 100 and the target stack module 100 can be lifted, moved, and lowered using power provided by a motor to achieve the position swap.

[0101] Optionally, the required gravity bearing capacity of the hook unit 210 and the track unit 220 is between 5 tons and 20 tons. All parameters must comply with the national standard GB / T3811-20082. If the mobile module adopts a bridge crane, it must comply with GB / T14405-2011. If the mobile module adopts a gantry crane, it must comply with GB / T14406-2011.

[0102] The length of the built-in container of the stack module 100 can be greater than or equal to 2400mm, the width can be greater than or equal to 1300mm, and the height can be determined according to the number of components to be stored. For example, the height can be designed to store more than or equal to ten components.

[0103] In other embodiments, the moving module can employ a ground-laid stacking track to control the stacking module 100 to be replaced and the target stacking module 100 to run on the ground track to exchange their positions. The moving module can also configure each processing module as an aerial assembly line, allowing the photovoltaic modules to flow on the aerial assembly line, thereby directly moving the modules to replace the positions of the stacking module 100 to be replaced and the target stacking module 100. Depending on the desired mobility scheme for the stacking module 100, the movable operation of the stacking module 100 provided in this embodiment, combined with the movement strategy between the stacking modules 100 provided by the above methods, makes the movable stacking of photovoltaic modules convenient, highly operable, highly automated, and highly efficient.

[0104] In one embodiment, a computer device is provided, including a memory and a processor. The memory stores a computer program, and the processor executes the computer program to implement the steps of the method provided in the above embodiments.

[0105] In one embodiment, a computer-readable storage medium is provided having a computer program stored thereon, which, when executed by a processor, implements the steps of the method provided in the above embodiments.

[0106] Any references to memory, storage, databases, or other media used in this application may include non-volatile and / or volatile memory. Suitable non-volatile memory may include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM), or flash memory. Volatile memory may include random access memory (RM), which is used as external cache memory. By way of illustration and not limitation, RM is available in a variety of forms, such as static RM (SRM), dynamic RM (DRM), synchronous DRM (SDRM), dual data rate SDRM (DDR SDRM), enhanced SDRM (ESDRM), synchronous link DRM (SLDRM), ROMbus direct RM (RDRM), direct memory bus dynamic RM (DRDRM), and memory bus dynamic RM (RDRM).

[0107] It should be understood that although the steps in the flowchart are shown sequentially as indicated by the arrows, these steps are not necessarily executed in the order indicated by the arrows. Unless explicitly stated herein, there is no strict order restriction on the execution of these steps, and they can be executed in other orders. Moreover, at least some steps in the flowchart may include multiple steps or stages, which are not necessarily completed at the same time, but can be executed at different times. The execution order of these steps or stages is not necessarily sequential, but can be performed alternately or in turn with other steps or at least some of the steps or stages in other steps.

[0108] In the description of this specification, the references to terms such as "some embodiments," "other embodiments," "ideal embodiments," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example that are included in at least one embodiment or example of this application. In this specification, the illustrative descriptions of the above terms do not necessarily refer to the same embodiments or examples.

[0109] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features of the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0110] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A method for stacking photovoltaic modules, characterized in that, include: Determine the capacity status of the stack module to be replaced among multiple stack modules, where each stack module is used to store the photovoltaic module to be processed in the corresponding processing module; In the event that the capacity status is in an abnormal state, the target stack module that meets the preset replacement conditions will be swapped with the stack module to be replaced. The target stack module includes any stack module other than the stack module to be replaced among the plurality of stack modules. The processing modules are cascaded together, and determining the capacity status of the stack module to be replaced among the multiple stack modules includes: Obtain the first production quantity of the upstream processing module adjacent to the current processing module, and obtain the second production quantity of the downstream processing module adjacent to the current processing module, wherein the current processing module corresponds to the stack module to be replaced; The capacity status of the stack module to be replaced is determined based on the first stack quantity of the stack module to be replaced and the comparison result between the first production quantity and the second production quantity. When the capacity status is in an abnormal state, the target stack module that meets the preset replacement conditions is swapped with the stack module to be replaced, including: Among multiple stack modules other than the stack module to be replaced, if the first state information of the candidate stack module is greater than the second state information of the remaining stack modules, the candidate stack module is determined as the target stack module. Wherein, the first status information is the difference between the second stack number of the candidate stack module and the first stack number of the stack module to be replaced, and the second status information is the difference between the third stack number of the remaining stack modules and the first stack number of the stack module to be replaced.

2. The photovoltaic module stacking method according to claim 1, characterized in that, The abnormal state includes a full material state. Determining the capacity state of the stack module to be replaced based on the first stack quantity of the stack module to be replaced and the comparison result between the first production quantity and the second production quantity includes: When the first stack quantity of the stack module to be replaced is greater than or equal to a first preset value, and when the first production quantity is greater than the second production quantity, it is determined that the capacity status of the stack module to be replaced is in the full-material state. If the first stack quantity of the stack module to be replaced is greater than or equal to a first preset value, and the first production quantity is less than the second production quantity, it is determined that the capacity status of the stack module to be replaced is in a normal state.

3. The photovoltaic module stacking method according to claim 1, characterized in that, The abnormal state includes an idle state. Determining the capacity state of the stack module to be replaced based on the first stack quantity of the stack module to be replaced and the comparison between the first production quantity and the second production quantity includes: If the first stack quantity of the stack module to be replaced is less than or equal to the second preset value, and the first production quantity is greater than the second production quantity, it is determined that the capacity status of the stack module to be replaced is in a normal state. If the first stack quantity of the stack module to be replaced is less than or equal to the second preset value, and the first production quantity is less than the second production quantity, it is determined that the capacity status of the stack module to be replaced is in the idle state.

4. The photovoltaic module stacking method according to claim 1, characterized in that, When there are multiple candidate stack modules, determining the candidate stack module as the target stack module when the first state information of the candidate stack module is greater than the second state information of the remaining stack modules, excluding the stack module to be replaced, includes: If the comparison result between the third state information and the fourth state information of any candidate stack module meets the preset comparison conditions, the candidate stack module is determined as the target stack module. Wherein, the third state information is the third production quantity of the upper-level processing module adjacent to the processing module corresponding to any candidate stack module, and the fourth state information is the fourth production quantity of the lower-level processing module adjacent to the processing module corresponding to any candidate stack module.

5. The photovoltaic module stacking method according to claim 4, characterized in that, The preset comparison conditions include: when the capacity state is at full capacity, the third state information is less than the fourth state information; and When the capacity status is in an idle state, the third state information is greater than the fourth state information.

6. A stacking device for photovoltaic modules, characterized in that, include: Multiple stack modules, each stack module being used to store photovoltaic modules to be processed by the corresponding processing module; The determination module is used to determine the capacity status of the stack module to be replaced among multiple stack modules; A moving module is used to swap the positions of a target stack module that meets preset replacement conditions with the stack module to be replaced when the capacity status is in an abnormal state. The target stack module includes any stack module other than the stack module to be replaced among the plurality of stack modules. The processing modules are cascaded together. The determining module is also used to obtain the first production quantity of the upper-level processing module adjacent to the current processing module and the second production quantity of the lower-level processing module adjacent to the current processing module. The current processing module corresponds to the stack module to be replaced. The module determines the capacity status of the stack module to be replaced based on the first stack quantity of the stack module to be replaced and the comparison result between the first production quantity and the second production quantity. The moving module is also used to determine the candidate stack module as the target stack module when the first state information of the candidate stack module is greater than the second state information of the remaining stack modules among a plurality of stack modules other than the stack module to be replaced. Wherein, the first status information is the difference between the second stack number of the candidate stack module and the first stack number of the stack module to be replaced, and the second status information is the difference between the third stack number of the remaining stack modules and the first stack number of the stack module to be replaced.

7. A computer device comprising a memory and a processor, wherein the memory stores a computer program, characterized in that, When the processor executes the computer program, it implements the steps of the method according to any one of claims 1 to 5.

8. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by a processor, it implements the steps of the method according to any one of claims 1 to 5.

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