Photovoltaic module surface detection system and detection method thereof

Abstract

The present invention provides a photovoltaic module surface detection system and a detection method thereof applied to the field of photovoltaic module detection. The system comprises an input module, a transfer unit, a flip module, a detection module, a repair welding module, an output module and a control module. The detection module can be used to detect a battery string after string welding, so as to detect whether there is a cold weld or other defects, and to troubleshoot the problems of the battery panel as early as possible. By setting up the repair welding module, automatic detection, positioning and repair welding can be performed on welding strips with cold welds, thereby saving labor costs. By setting up installation rollers, the battery string can be efficiently oriented to different execution stations, so that the overall system occupies less space and is more efficient.

Description

Technical Field

[0001] The present invention relates to the field of photovoltaic module detection, and in particular to a photovoltaic module surface detection system and a detection method thereof. Background Art

[0002] In the field of photovoltaic module production, the string welding process is to weld each battery cell in sequence into a row through welding ribbons to obtain a battery cell string, and a cold weld refers to the phenomenon that the connection between the welding ribbon and the battery cell is not firm during the welding process of the module, resulting in poor contact; battery cell cold welds generally exist in the following situations:

[0003] 1. The soldering tape on the front of the battery cell is not welded to the soldering tape on the battery cell.

[0004] 2. The head is hollow, and the soldering ribbon at the head of the battery cell is not welded to the soldering ribbon of the battery cell.

[0005] 3. The soldering tape on the back of the battery cell fails to be soldered to the soldering tape on the back of the battery cell.

[0006] 4. The tail is hollow, and the solder strip at the tail of the battery cell is not welded to the solder strip of the battery cell.

[0007] Moreover, there are few existing processes for immediately testing the battery strings after string welding. The set detection is often only carried out manually, or uniformly tested after lamination. The main reasons for not setting up detection are: 1. The operation is difficult. Since the battery strings after string welding do not have unified electrodes, it is difficult to make conductive connections with each battery string. The laminated photovoltaic modules have unified electrode sheets or junction boxes for easy electrical connection; 2. It is believed that unified testing is more efficient. Through unified testing, unqualified photovoltaic modules can be uniformly checked and screened before leaving the factory. Removing unqualified modules can speed up production efficiency and save costs. If the defect of the photovoltaic module is a cold solder joint, if you want to disassemble the laminated module, the process is more complicated, so this step also adds work in another aspect. Cold solder joints are mainly caused by inadequate execution of the string welding process. Therefore, a detection system can be developed to immediately perform detection on the battery strings after string welding. Summary of the invention

[0008] The purpose of the present invention is to address the existing deficiencies and propose a photovoltaic module surface detection system and detection method thereof.

[0009] In order to overcome the shortcomings of the prior art, the present invention adopts the following technical solutions:

[0010] A photovoltaic module surface detection system comprises: a machine room;

[0011] Input module, used to feed the battery cells to be inspected;

[0012] A transfer unit, used to transfer the battery cells from the input module to the flip module;

[0013] Flip module, used to adjust the position and orientation of the battery cell;

[0014] A detection module is used to detect defects in the battery cell and analyze whether the battery cell has defects;

[0015] The repair welding module is used to repair the welding of specific battery cells.

[0016] Output module, used to transport the battery cells out;

[0017] The control module is communicatively connected with the input module, the transfer unit, the flip module, the detection module, the repair welding module and the output module;

[0018] The transfer unit includes a first truss, a first mobile unit, a lifting unit and a first fixed unit, wherein the first mobile unit is arranged on the first truss and is used to drive the first fixed unit to move, the lifting unit is arranged on the first mobile unit and is used to drive the first fixed unit to lift and lower, and the first fixed unit is arranged on the lifting unit and is used to adsorb and fix the battery sheet;

[0019] The detection module includes a first infrared camera, an image processing unit and an analysis unit. The first infrared camera is installed on the machine room, and the first infrared camera is communicatively connected with the image processing unit and the analysis module. The first infrared camera is used to collect infrared images of the battery cells on the flip module. The image processing unit is configured to perform image preprocessing on the collected images to generate preprocessed images. The analysis unit is configured to compare and analyze the preprocessed images to determine whether there are defects and generate analysis results.

[0020] Furthermore, the flip module includes a flip unit and a second fixing unit, the flip unit is used to adjust the position of the second fixing unit, the second fixing unit is arranged on the flip unit, and the second fixing unit is used to adsorb and fix the battery cell.

[0021] Further, the repair welding module includes a second moving unit, a welding unit and a visual positioning unit, the second moving unit is used to drive the welding unit and the visual positioning unit to move, the welding unit is used to perform repair welding, and the visual positioning unit is used to identify and locate the position of the virtual welding strip;

[0022] The visual positioning unit is configured as a camera and an irradiation lamp, and the camera and the irradiation lamp are arranged on the second mounting platform;

[0023] The welding unit comprises a welding gun, a telescopic mechanism, and a welding strip supply mechanism. The welding strip supply mechanism is used to supply welding strips. The telescopic mechanism is used to drive the welding gun to move forward and backward. The welding gun is used to perform welding.

[0024] Furthermore, the control module includes a recording unit, a communication unit, and a display unit. The recording unit is used to store battery cell image records and device operation status buffer information. The communication unit is used to send control instructions or connect to external devices to achieve communication. The display unit is used to display control information and collected captured images.

[0025] The detection method of the photovoltaic module surface detection system is characterized by comprising:

[0026] S1, transporting the loading parts, transporting the battery cells that have completed the string welding process to the input module for transportation, and stopping the transportation after transporting to the designated loading area;

[0027] S2, transfer, the transfer unit transfers the battery cells in the loading area from the input module to the flip module, and the flip module fixes the battery cells;

[0028] S3, conversion and detection, the flip module drives the battery cell to rotate so that the battery cell faces the detection module, and the power supply module is connected to the welding strips at both ends of the battery cell to supply power to the battery cell, so that the battery cell emits electroluminescence, and the detection module takes pictures and compares and analyzes whether there are defects in the battery cell, and generates analysis results;

[0029] S3a-1, defect type identification, if the analysis result shows that the battery cell has defects, the cell number of the defective battery panel is sent to the recording unit for recording, and the defect type is determined at the same time to generate an analysis result. If the defect type determined by the analysis result is a cold solder joint and meets the standard number requirement for cold solder joint repair, the battery cell is directed to the repair soldering module and the process S3a-2 is executed. If the defect type determined by the analysis result is not a cold solder joint, the battery cell is sent out through the output module for manual review;

[0030] S3a-2, problem location, by recording the cell number of the corresponding defective battery panel stored in the recording unit to determine the area where the defective solder strip is located, the control module controls the second moving unit to drive the second mounting platform to move to the defect area, and the visual positioning unit is used to shoot and identify the detection area, so as to perform visual inspection and comparison to see if there are any abnormalities in each solder strip in the detection area;

[0031] S3a-3, perform repair welding, after the second moving unit drives the welding gun to move to the position of the defective welding strip, the telescopic unit starts to drive the battery cell close to the welding gun, the welding strip supply mechanism supplies the welding strip, and the welding gun performs welding to weld the welding strip to the position of the defective welding strip for repair welding;

[0032] S3a-4 re-inspection: after the repair welding is completed, continue to energize the battery cell to take pictures through the second infrared camera, and then send it to the analysis module for defect analysis to analyze whether the defect characteristics still exist. If they still exist, turn the battery cell over and inspect the welding strips connected to the same battery panel. Repeat the process S3a-2 and S3a-3. If no abnormal welding strips are found after the inspection on the other side, the battery cell is sent out through the output module.

[0033] S3b, qualified output, if the analysis results show that the battery cell has no defects, the battery cell is placed in the output module for delivery.

[0034] Furthermore, when the analysis results determine that the defect type is a cold solder joint, the total number of defective panels and the number of defective rows with cold solder joint features in the image are statistically confirmed. When the number of rows of defective panels is greater than the total number of rows*k, or the total number of defective panels is greater than the total number of battery panels*b, the battery cell is sent out by the output module for manual review. If the above conditions are not met, the repair soldering process is performed on the battery cell.

[0035] Furthermore, a specific method for detecting whether the solder strip is abnormal is as follows: the solder strip to be detected is irradiated with an irradiation lamp, and the solder strip to be detected is photographed with a camera to generate a detection image. In the detection image, the solder strip is reflected by the irradiation to form a highlight area. When the solder strip is protruding or detached from the board, the shape of the highlight area is compared with the highlight area of ​​a normal solder strip to see if there is a difference. This is used as the first judgment feature for detecting abnormal solder strips. At the same time, since the irradiation lamp is set at an angle, the protruding part generates a solder strip protruding shadow area on the battery board after irradiation. This is used as the second judgment feature for detecting abnormal solder strips. When the first judgment feature or the second judgment feature is detected, it is judged that the solder strip is abnormal.

[0036] The beneficial effects achieved by the present invention are:

[0037] The detection module can be used to detect the battery string after string welding, so as to detect whether there is cold welding or other defects, and to check the problems of the battery panel at an early stage. By setting the repair welding module, the welding strip with cold welding can be automatically detected, positioned and repaired, saving labor costs. By setting the first fixing unit and the second fixing unit, the battery string can be firmly fixed. By setting the flip module, the battery string can be transferred to different workstations, and the battery string can be flipped at the same time to perform detection and repair welding on the back. By setting the installation roller, the battery string can be efficiently oriented to different execution stations, so that the overall footprint of the system is smaller and the efficiency is higher. The power supply module is provided on the installation roller to perform one-to-one matching connection with each battery string to perform electroluminescence detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] The present invention can be further understood from the following description in conjunction with the accompanying drawings. The components in the figures are not necessarily drawn to scale, but the emphasis is placed on illustrating the principles of the embodiments. In different views, the same reference numerals designate corresponding parts.

[0039] Figure 1 It is a structural schematic diagram of the present invention.

[0040] Figure 2 It is a schematic diagram of the structure in the machine room of the present invention.

[0041] Figure 3 for Figure 2 Schematic diagram of the enlarged structure marked A.

[0042] Figure 4 It is a structural schematic diagram of the second fixing unit and the power supply module of the present invention.

[0043] Figure 5 It is a schematic structural diagram of the second mobile unit of the present invention.

[0044] Figure 6 It is a schematic diagram of the local structure of the repair welding module of the present invention.

[0045] Figure 7 It is a flowchart of the detection method of the present invention.

[0046] Figure 8 This is a schematic diagram of the analysis module of the present invention identifying the presence of a cold solder joint in a pre-processed image.

[0047] Fig. 9 This is a schematic diagram of the solder strip anomaly captured by the camera of the present invention.

[0048] In the figure: 1 input module, 2 transfer unit, 21 first truss, 22 first mobile unit, 23 lifting unit, 24 first fixed unit, 3 flip module, 31 flip unit, 311 mounting roller, 312 movable splint, 313 fixed seat, 314 second drive motor, 32 second fixed unit, 4 detection module, 5 repair welding module, 51 second mobile unit, 511 second mounting frame, 512 X-axis moving mechanism, 513 Y-axis moving mechanism, 514 second mounting table, 521 welding gun, 522 telescopic mechanism, 523 welding tape reel, 524 traction device, 525 limit rod, 531 camera, 532 irradiation lamp, 6 output module, 7 control module, 8 machine room. DETAILED DESCRIPTION

[0049] In order to make the purpose, technical solutions and advantages of the present invention more clear, the present invention is further described in detail in conjunction with its embodiments below; it should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention. For those skilled in the art, other systems, methods and / or features of this embodiment will become apparent after reviewing the following detailed description. It is intended that all such additional systems, methods, features and advantages are included in this specification, included within the scope of the present invention, and protected by the appended claims. Additional features of the disclosed embodiments are described in the following detailed description, and these features will be apparent from the following detailed description.

[0050] The same or similar numbers in the drawings of the embodiments of the present invention correspond to the same or similar parts; in the description of the present invention, it should be understood that if the terms "upper", "lower", "left", "right" and the like indicate directions or positional relationships based on the directions or positional relationships shown in the drawings, it is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or component referred to must have a specific direction, be constructed and operated in a specific direction. Therefore, the terms describing the positional relationship in the drawings are only used for illustrative purposes and cannot be understood as limitations on this patent. For ordinary technicians in this field, the specific meanings of the above terms can be understood according to specific circumstances.

[0051] Embodiment 1.

[0052] like Figure 1 , Figure 2 As shown, a photovoltaic module surface detection system and detection method thereof include: a machine room 8;

[0053] Input module 1, used to feed the battery cells to be inspected;

[0054] The transfer unit 2 is used to transfer the battery cells from the input module 1 to the flip module 3;

[0055] Flip module 3, used to adjust the position and orientation of the battery cell;

[0056] Detection module 4, used to perform defect detection on the battery cell and analyze whether the battery cell has defects;

[0057] The repair welding module 5 is used to repair the cold welds of the battery cells that meet the standard number of cold weld repair welding requirements.

[0058] Output module 6, used to transport the battery cells out;

[0059] The control module 7 is communicatively connected with the input module 1, the transfer unit 2, the flip module 3, the detection module 4, the repair welding module 5 and the output module 6;

[0060] The input module 1 and the output module 6 are both configured as conveyor belt devices;

[0061] The transfer unit 2 includes a first truss 21, a first mobile unit 22, a lifting unit 23 and a first fixed unit 24. The first mobile unit 22 is arranged on the first truss 21 and is used to drive the first fixed unit 24 to move. The lifting unit 23 is arranged on the first mobile unit 22 and is used to drive the first fixed unit 24 to lift and lower. The first fixed unit 24 is arranged on the lifting unit 23 and is used to adsorb and fix the battery sheet.

[0062] The detection module 4 includes a first infrared camera, an image processing unit and an analysis unit. The first infrared camera is installed on the machine room 8, and the first infrared camera is communicatively connected with the image processing unit and the analysis module. The first infrared camera is used to collect infrared images of the battery cells on the flip module 3. The image processing unit is configured to perform image preprocessing on the collected images to generate preprocessed images. The analysis unit is configured to compare and analyze the preprocessed images to determine whether there are defects and generate analysis results.

[0063] The flip module 3 includes a flip unit 31 and a second fixing unit 32. The flip unit 31 is used to adjust the position of the second fixing unit 32. The second fixing unit 32 is arranged on the flip unit 31. The second fixing unit 32 is used to adsorb and fix the battery cell.

[0064] The repair welding module 5 includes a second moving unit 51, a welding unit and a visual positioning unit, wherein the second moving unit 51 is used to drive the welding unit and the visual positioning unit to move, the welding unit is used to perform repair welding, and the visual positioning unit is used to identify and locate the position of the cold welding strip;

[0065] The visual positioning unit is configured as a camera 531 and an irradiation lamp 532, and the camera 531 and the irradiation lamp 532 are arranged on the second mounting platform 514;

[0066] The welding unit includes a welding gun 521, a telescopic mechanism 522, and a welding strip supply mechanism. The welding strip supply mechanism is used to supply welding strips. The telescopic mechanism 522 is used to drive the welding gun 521 to move forward and backward. The welding gun 521 is used to perform welding.

[0067] The control module 7 includes a recording unit, a communication unit, and a display unit. The recording unit is used to store battery cell image records and device operation status buffer information. The communication unit is used to send control instructions or connect to external devices to achieve communication. The display unit is used to display control information and collected shooting images.

[0068] Embodiment 2: This embodiment is a further description of the above embodiment. It should be understood that this embodiment includes all the above technical features and is further described in detail:

[0069] Further integration Figure 3 , Figure 4 , Figure 5 , Figure 6 As shown, a photovoltaic module surface detection system includes: a machine room 8;

[0070] Input module 1, used to feed the battery cells to be inspected;

[0071] The transfer unit 2 is used to transfer the battery cells from the input module 1 to the flip module 3;

[0072] Flip module 3, used to adjust the position and orientation of the battery cell;

[0073] Detection module 4, used to perform defect detection on the battery cell and analyze whether the battery cell has defects;

[0074] The repair welding module 5 is used to carry out repair welding on a specific battery cell.

[0075] Output module 6, used to transport the battery cells out;

[0076] The control module 7 is communicatively connected with the input module 1, the transfer unit 2, the flip module 3, the detection module 4, the repair welding module 5 and the output module 6;

[0077] The input module 1 and the output module 6 are both configured as conveyor belt devices;

[0078] The transfer unit 2 includes a first truss 21, a first mobile unit 22, a lifting unit 23 and a first fixed unit 24. The first mobile unit 22 is arranged on the first truss 21 and is used to drive the first fixed unit 24 to move. The lifting unit 23 is arranged on the first mobile unit 22 and is used to drive the first fixed unit 24 to lift and lower. The first fixed unit 24 is arranged on the lifting unit 23 and is used to adsorb and fix the battery sheet.

[0079] The first moving unit 22 is configured as a cylinder-driven slide mechanism, and the first moving unit 22 includes a first telescopic cylinder, a first mounting platform, a slider, and a guide rail. The first mounting platform is connected to the slider, and the first telescopic cylinder is used to push the first mounting platform and the slider to move along the guide rail. The lifting unit 23 is arranged on the first mounting platform;

[0080] The detection module 4 includes a first infrared camera, an image processing unit and an analysis unit. The first infrared camera is installed on the machine room 8, and the first infrared camera is communicatively connected with the image processing unit and the analysis module. The first infrared camera is used to collect infrared images of the battery cells on the flip module 3. The image processing unit is configured to perform image preprocessing on the collected images to generate preprocessed images. The analysis unit is configured to compare and analyze the preprocessed images to determine whether there are defects and generate analysis results.

[0081] The flip module 3 includes a flip unit 31 and a second fixing unit 32. The flip unit 31 is used to adjust the position of the second fixing unit 32. The second fixing unit 32 is arranged on the flip unit 31. The second fixing unit 32 is used to adsorb and fix the battery cell.

[0082] The second fixing units 32 can be arranged in two groups or four groups. When arranged in two groups, the two groups of second fixing units 32 are symmetrically arranged on the installation roller 311. When arranged in four groups, they are arranged at equal angles on four surfaces of the installation roller 311.

[0083] The first fixing unit 24 and the second fixing unit 32 are both vacuum suction cup devices, and both include a first mounting frame, a vacuum generator, a connecting pipe and a suction cup. The first mounting frame of the second fixing unit 32 is arranged on the mounting roller 311, the vacuum transmitter is installed on the first mounting frame, and the suction cup is arranged on the first mounting frame and is connected to the vacuum generator through the connecting pipe.

[0084] The suction cups are arranged in a matrix on the first mounting frame, and the number of rows of the suction cups corresponds to the number of battery strings, so that multiple battery strings can be adsorbed and fixed, thereby improving production inspection efficiency;

[0085] The flip unit 31 includes a second truss, a first drive motor and a mounting roller 311, the mounting roller 311 is rotatably mounted on the second truss, the first drive motor is fixedly mounted on the second truss, and the first drive motor is transmission-connected to the mounting roller 311 to drive the mounting roller 311 to rotate;

[0086] The installation roller 311 is a square roller, and the installation roller 311 is provided with multiple planes;

[0087] The installation roller 311 is provided with a power supply module, and the power supply module is used to connect with the welding strips at both ends of the battery sheet to provide a constant power supply;

[0088] The power supply module includes a clamping plate mechanism, an electrode sheet and a constant power supply, wherein the electrode sheet is arranged on the clamping plate mechanism, and the constant power supply is electrically connected to the electrode sheet, so that when the electrode sheet is connected to the welding strip of the battery sheet, it is used to provide a forward bias voltage to the battery sheet so that the battery sheet is electroluminescent, and the clamping plate mechanism is used to drive the electrode sheet to move;

[0089] The clamping plate mechanism includes a movable clamping plate 312, a fixed seat 313, and a second driving motor 314. The fixed seat 313 is fixedly arranged on the installation roller 311. The movable clamping plate 312 is rotatably arranged on the fixed seat 313 and is connected to the second driving motor 314 through a transmission gear. The second driving motor 314 is used to drive the movable clamping plate 312 to rotate so as to realize opening and closing. The electrode sheet is arranged on the movable clamping plate 312.

[0090] The clamping mechanism and the electrode sheet are provided in two groups, which are symmetrically arranged on both sides of the second fixing unit 32, and are used to connect with the welding strips at both ends of the battery string to form positive and negative electrodes;

[0091] The number of electrode sheets on the same set of clamping mechanisms matches the number of battery strings that can be fixed by the second fixing unit 32;

[0092] The repair welding module 5 includes a second moving unit 51, a welding unit and a visual positioning unit, wherein the second moving unit 51 is used to drive the welding unit and the visual positioning unit to move, the welding unit is used to perform repair welding, and the visual positioning unit is used to identify and locate the position of the cold welding strip;

[0093] The second moving unit 51 includes a second mounting frame 511, an X-axis moving mechanism 512, a Y-axis moving mechanism 513 and a second mounting platform 514 connected in sequence, wherein the X-axis moving mechanism 512 and the Y-axis moving mechanism 513 are configured to drive the second mounting platform 514 to move along the X-axis and Y-axis directions;

[0094] The X-axis moving mechanism 512 and the Y-axis moving mechanism 513 are both configured as lead screw slider modules;

[0095] The visual positioning unit is configured as a camera 531 and an irradiation lamp 532, and the camera 531 and the irradiation lamp 532 are arranged on the second mounting platform 514;

[0096] The shooting angle of the camera 531 is tilted, and the angle between the shooting direction of the camera 531 and the plate plane of the second mounting plate is 30°-60°;

[0097] The repair welding module 5 is also provided with a second infrared camera, and the second infrared camera is arranged on a second mounting platform 514;

[0098] The welding unit includes a welding gun 521, a telescopic mechanism 522, and a welding strip supply mechanism. The welding strip supply mechanism is used to supply welding strips. The telescopic mechanism 522 is used to drive the welding gun 521 to move forward and backward. The welding gun 521 is used to perform welding.

[0099] The telescopic mechanism 522 includes a second telescopic cylinder, a guide rail and a third mounting platform. The second telescopic cylinder and the guide rail are fixedly arranged on the second mounting platform 514. The third mounting platform is connected to the second telescopic cylinder, and the third mounting platform is provided with a through hole matching the guide rail.

[0100] The welding tape supply mechanism includes a welding tape reel 523, a traction device 524, and a limiting rod 525. The welding tape reel 523 is arranged on the second mounting platform 514, and the welding tape reel 523 is used to store welding tape. The traction device 524 is arranged on the third mounting platform, and is used to limit the welding tape and pull it to the limiting rod 525. The limiting rod 525 is arranged on the third mounting platform and in front of the traction device 524. The limiting rod 525 is used to guide the welding tape sent by the traction device 524 to the gun head of the welding gun 521;

[0101] The control module 7 includes a recording unit, a communication unit, and a display unit. The recording unit is used to store battery cell image records and device operation status buffer information. The communication unit is used to send control instructions or connect to external devices to achieve communication. The display unit is used to display control information and collected shooting images.

[0102] The display unit is configured as a touch display screen;

[0103] Embodiment 3: This embodiment is a further description of the above embodiment. It should be understood that this embodiment includes all the above technical features and is further described in detail:

[0104] Combination Figure 7 As shown, the detection method of the photovoltaic module surface detection system includes:

[0105] S1, transporting and loading, transporting the battery cells that have completed the string welding process to the input module 1 for transportation, and stopping the transportation after transporting to the designated loading area;

[0106] S2, transfer, the transfer unit 2 transfers the battery cells in the loading area from the input module 1 to the flip module 3, and the flip module 3 fixes the battery cells;

[0107] S3, conversion and detection, the flip module 3 drives the battery cell to rotate so that the battery cell faces the detection module 4, and the power supply module is connected to the welding strips at both ends of the battery cell to supply power to the battery cell, so that the battery cell generates electroluminescence, and the detection module 4 takes pictures and compares and analyzes whether there are defects in the battery cell, and generates analysis results;

[0108] Image acquisition, sending the image collected by the first infrared camera to the image processing unit, the image processing unit will collect the image for splicing, sharpening enhancement, dividing the image cells and cell numbering, generate a pre-processed image, send the pre-processed image to the display unit for display and to the analysis module for defect analysis;

[0109] The specific method of dividing the image cells and numbering the cells is: taking a single minimum battery panel installed in the battery cell image as a unit to divide the cells, and numbering each cell in sequence;

[0110] S3a-1, defect type identification, if the analysis result shows that the battery cell has defects, the cell number of the defective battery panel is sent to the recording unit for recording, and the defect type is determined at the same time to generate an analysis result. If the defect type determined by the analysis result is a cold solder joint and meets the standard number requirement for cold solder joint repair, the battery cell is directed to the repair soldering module 5 and the process S3a-2 is executed. If the defect type determined by the analysis result is not a cold solder joint, the battery cell is sent out through the output module 6 for manual review;

[0111] The image feature recognition principle of the defect recognition of the detection module 4 is realized by using the image algorithm of the convolutional neural network;

[0112] The standard number requirement for re-welding is: when the analysis result determines that the defect type is a cold weld, the total number of defective panels and the number of defective rows with cold weld characteristics in the image are statistically confirmed. When the number of rows of defective panels is greater than the total number of rows*k, or the total number of defective panels is greater than the total number of battery panels*b, the battery cell is sent out by the output module 6 for manual review. If the above conditions are not met, the re-welding process is performed on the battery cell;

[0113] In this embodiment, k=60%, b=10%;

[0114] S3a-2, problem location, by recording the cell number of the corresponding defective battery panel stored in the recording unit to determine the area where the defective solder strip is located, the control module 7 controls the second moving unit 51 to drive the second mounting platform 514 to move to the defect area, and the visual positioning unit is used to shoot and identify the detection area, so as to perform visual inspection and comparison to see if there are any abnormalities in each solder strip in the detection area;

[0115] like Figure 8 As shown, the detection area is determined in the following manner: the image feature of the virtual solder joint is the appearance of a symmetrical dark area along the main grid direction, the dark area is marked as the detection area, and the solder strips involved in the detection area are all marked as solder strips to be detected;

[0116] A specific method for detecting whether the solder strip is abnormal is as follows: the solder strip to be detected is irradiated by the irradiation lamp 532, and the solder strip to be detected is photographed by the camera 531 to generate a detection image. In the detection image, the solder strip is irradiated to reflect light to form a highlight area. When the solder strip is convex or detached from the board, the shape of the highlight area is compared with the highlight area of ​​the normal solder strip to see whether there is a difference, which is used as the first judgment feature for detecting the abnormality of the solder strip. At the same time, since the irradiation lamp 532 is set at an angle, the convex part generates a solder strip convex shadow area on the battery board after irradiation, which is used as the second judgment feature for detecting the abnormality of the solder strip. When the first judgment feature or the second judgment feature is detected, it is judged that the solder strip is abnormal, such as Fig. 9 The figure shows the effect of normal and abnormal welding strips;

[0117] When the soldering strip that needs to be re-welded is on the side facing the installation roller 311, the battery cell can be turned over and then re-welded;

[0118] The specific method of flipping is as follows: the flipping module 3 places the battery cell to be flipped on the output module 6, the output module 6 transports the battery cell toward the input module 1, and the input module 1 also cooperates with the movement to transport it to the loading area, and then the transfer unit 2 transports the battery cell from the input module 1 to the flipping module 3 for fixing, so that the other side of the battery cell faces outward;

[0119] S3a-3, perform repair welding, after the second moving unit 51 drives the welding gun 521 to move to the position of the defective welding strip, the telescopic unit starts to drive the battery cell close to the welding gun 521, the welding strip supply mechanism supplies the welding strip, and the welding gun 521 performs welding to weld the welding strip to the position of the defective welding strip for repair welding;

[0120] During the welding process, the welding gun 521 is driven by the second moving unit 51 to move along the welding path;

[0121] S3a-4 re-inspection: after the repair welding is completed, continue to energize the battery cell to take pictures through the second infrared camera, and then send it to the analysis module for defect analysis to analyze whether the defect characteristics still exist. If they still exist, turn the battery cell over and inspect the welding strips connected to the same battery panel. Repeat the process S3a-2 and S3a-3. If no abnormal welding strips are found after the inspection on the other side, the battery cell is sent out through the output module 6.

[0122] S3b, qualified output, if the analysis result shows that the battery cell has no defects, the battery cell is placed in the output module 6 for delivery;

[0123] In the above method flow, when the battery cell is sent out by the output module 6, all steps of the system for the battery cell are completed;

[0124] The power supply module does not energize the battery cells except during the detection process.

[0125] Although the present invention has been described above with reference to various embodiments, it should be understood that many changes and modifications may be made without departing from the scope of the present invention. That is, the methods, systems and devices discussed above are examples. Various configurations may appropriately omit, replace or add various processes or components. For example, in alternative configurations, the method may be performed in an order different from the order described, and / or various components may be added, omitted and / or combined. Moreover, the features described with respect to certain configurations may be combined in various other configurations, such as different aspects and elements of the configurations may be combined in a similar manner. In addition, the elements therein may be updated as the technology develops, i.e., many elements are examples and do not limit the scope of the present disclosure or claims.

[0126] Specific details are given in the specification to provide a thorough understanding of the exemplary configurations including implementations. However, the configurations may be practiced without these specific details. For example, well-known circuits, processes, algorithms, structures, and techniques have been shown without unnecessary details to avoid obscuring the configurations. This description provides only example configurations and does not limit the scope, applicability, or configurations of the claims. On the contrary, the foregoing description of the configurations will provide those skilled in the art with an enabling description for implementing the described techniques. Various changes may be made to the functions and arrangements of the elements without departing from the spirit or scope of the present disclosure.

[0127] In summary, it is intended that the above detailed description is considered to be illustrative rather than restrictive, and it should be understood that the above embodiments should be understood to be only used to illustrate the present invention and not to limit the scope of protection of the present invention. After reading the contents of the present invention, the technician can make various changes or modifications to the present invention, and these equivalent changes and modifications also fall within the scope defined by the claims of the present invention.

Claims

1. A photovoltaic module surface detection system, characterized in that: include: Engine room; Input module, used to feed the battery cells to be inspected; A transfer unit, used for transferring the battery cells from the input module to the flip module; Flip module, used to adjust the position and orientation of the battery cell; A detection module is used to detect defects in the battery cell and analyze whether the battery cell has defects; A repair welding module is used to repair the cold welds of the battery cells that meet the standard number of cold weld repair welding requirements; Output module, used to transport the battery cells out; The control module is communicatively connected with the input module, the transfer unit, the flip module, the detection module, the repair welding module and the output module; The transfer unit includes a first truss, a first mobile unit, a lifting unit and a first fixed unit, wherein the first mobile unit is arranged on the first truss and is used to drive the first fixed unit to move, the lifting unit is arranged on the first mobile unit and is used to drive the first fixed unit to lift and lower, and the first fixed unit is arranged on the lifting unit and is used to adsorb and fix the battery sheet; The detection module includes a first infrared camera, an image processing unit and an analysis unit. The first infrared camera is installed on the machine room, and the first infrared camera is communicatively connected with the image processing unit and the analysis module. The first infrared camera is used to collect infrared images of the battery slices on the flip module. The image processing unit is configured to perform image preprocessing on the collected images to generate preprocessed images. The analysis unit is configured to compare and analyze the preprocessed images to determine whether there are defects and generate analysis results. The flip module includes a flip unit and a second fixing unit, wherein the flip unit is used to adjust the position of the second fixing unit, the second fixing unit is arranged on the flip unit, and the second fixing unit is used to adsorb and fix the battery cell; The flip unit includes a second truss, a first drive motor and a mounting roller, the mounting roller is rotatably arranged on the second truss, the first drive motor is fixedly mounted on the second truss, and the first drive motor is transmission-connected with the mounting roller to drive the mounting roller to rotate; The installation roller is a square roller, and the installation roller is provided with multiple planes; The installation roller is provided with a power supply module, and the power supply module is used to connect with the welding strips at both ends of the battery sheet to provide a constant power supply; The power supply module includes a clamping mechanism, an electrode sheet and a constant power supply. The electrode sheet is arranged on the clamping mechanism. The constant power supply is electrically connected to the electrode sheet, so that when the electrode sheet is connected to the welding strip of the battery sheet, it is used to provide a forward bias voltage to the battery sheet so that the battery sheet can be electroluminescent. The clamping mechanism is used to drive the electrode sheet to move.

2. A photovoltaic module surface detection system as claimed in claim 1, characterized in that: The repair welding module includes a second moving unit, a welding unit and a visual positioning unit, wherein the second moving unit is used to drive the welding unit and the visual positioning unit to move, the welding unit is used to perform repair welding, and the visual positioning unit is used to identify and locate the position of the virtual welding strip; The visual positioning unit is configured as a camera and an irradiation lamp, and the camera and the irradiation lamp are arranged on the second mounting platform; The welding unit includes a welding gun, a telescopic mechanism, and a welding strip supply mechanism, wherein the welding strip supply mechanism is used to supply welding strips, the telescopic mechanism is used to drive the welding gun to move forward and backward, and the welding gun is used to perform welding; The second moving unit comprises a second mounting frame, an X-axis moving mechanism, a Y-axis moving mechanism and a second mounting table connected in sequence, wherein the X-axis moving mechanism and the Y-axis moving mechanism are configured to drive the second mounting table to move along the X-axis and Y-axis directions; The X-axis moving mechanism and the Y-axis moving mechanism are both configured as lead screw slider modules; The visual positioning unit is configured as a camera and an irradiation lamp, and the camera and the irradiation lamp are arranged on the second mounting platform; The shooting angle of the camera is tilted, and the angle between the camera shooting direction and the plate plane of the second mounting plate is 30°-60°; The welding unit includes a welding gun, a telescopic mechanism, and a welding strip supply mechanism, wherein the welding strip supply mechanism is used to supply welding strips, the telescopic mechanism is used to drive the welding gun to move forward and backward, and the welding gun is used to perform welding; The telescopic mechanism includes a second telescopic cylinder, a guide rod and a third mounting platform. The second telescopic cylinder and the guide rod are fixedly arranged on the second mounting platform. The third mounting platform is connected to the second telescopic cylinder, and the third mounting platform is provided with a through hole matching the guide rod.

3. A photovoltaic module surface detection system as claimed in claim 1, characterized in that: The control module includes a recording unit, a communication unit, and a display unit. The recording unit is used to store battery cell image records and device operation status buffer information. The communication unit is used to send control instructions or connect to external devices to achieve communication. The display unit is used to display control information and collected captured images.

4. The detection method using the photovoltaic module surface detection system as claimed in claim 3 is characterized in that: include: S1, transporting the loading parts, transporting the battery cells that have completed the string welding process to the input module for transportation, and stopping the transportation after transporting to the designated loading area; S2, transfer, the transfer unit transfers the battery cells in the loading area from the input module to the flip module, and the flip module fixes the battery cells; S3, conversion and detection, the flip module drives the battery cell to rotate so that the battery cell faces the detection module, and the power supply module is connected to the welding strips at both ends of the battery cell to supply power to the battery cell, so that the battery cell emits electroluminescence, and the detection module takes pictures and compares and analyzes whether there are defects in the battery cell, and generates analysis results; S3a-1, defect type identification, if the analysis result shows that the battery cell has defects, the cell number of the defective battery panel is sent to the recording unit for recording, and the defect type is determined at the same time to generate an analysis result. If the defect type determined by the analysis result is a cold solder joint and meets the standard number requirement for cold solder joint repair, the battery cell is directed to the repair soldering module and the process S3a-2 is executed. If the defect type determined by the analysis result is not a cold solder joint, the battery cell is sent out through the output module for manual review; S3a-2, problem location, by recording the cell number of the corresponding defective battery panel stored in the recording unit to determine the area where the defective solder strip is located, the control module controls the second moving unit to drive the second mounting platform to move to the defect area, and the visual positioning unit is used to shoot and identify the detection area, so as to perform visual inspection and comparison to see if there are any abnormalities in each solder strip in the detection area; S3a-3, perform repair welding, after the second moving unit drives the welding gun to move to the position of the defective welding strip, the telescopic unit starts to drive the battery cell close to the welding gun, the welding strip supply mechanism supplies the welding strip, and the welding gun performs welding to weld the welding strip to the position of the defective welding strip for repair welding; S3a-4 re-inspection: after the repair welding is completed, continue to energize the battery cell to take pictures through the second infrared camera, and then send it to the analysis module for defect analysis to analyze whether the defect characteristics still exist. If they still exist, turn the battery cell over and inspect the welding strips connected to the same battery panel. Repeat the process S3a-2 and S3a-3. If no abnormal welding strips are found after the inspection on the other side, the battery cell is sent out through the output module. S3b, qualified output, if the analysis results show that the battery cell has no defects, the battery cell is placed in the output module for delivery.

5. The detection method of the photovoltaic module surface detection system according to claim 4, characterized in that: The standard number requirement for re-welding is: when the analysis result determines that the defect type is a cold solder joint, the total number of defective panels and the number of defective rows with cold solder joint features in the image are statistically confirmed. When the number of rows of defective panels is greater than the total number of rows*k, or the total number of defective panels is greater than the total number of battery panels*b, the battery cell is sent out by the output module for manual review. If the above conditions are not met, the re-welding process is performed on the battery cell, k=60%, b=10%.

6. The detection method of the photovoltaic module surface detection system according to claim 4, characterized in that: A specific method for detecting whether the solder strip is abnormal is as follows: the solder strip to be detected is irradiated with an irradiation lamp, and the solder strip to be detected is photographed with a camera to generate a detection image. In the detection image, the solder strip is irradiated and reflects light to form a highlight area. When the solder strip is protruding or detached from the board, the shape of the highlight area is compared with the highlight area of ​​a normal solder strip to see if there is a difference. This is used as the first judgment feature for detecting abnormal solder strips. At the same time, since the irradiation lamp is set at an angle, the protruding part generates a solder strip protruding shadow area on the battery board after irradiation. This is used as the second judgment feature for detecting abnormal solder strips. When the first judgment feature or the second judgment feature is detected, it is judged that the solder strip is abnormal.

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