Feeding method of photovoltaic module junction box

Abstract

The invention relates to a photovoltaic module junction box feeding method, which comprises the following steps of: firstly, randomly taking out junction boxes one by one from a material frame, and laying the junction boxes on an overturning platform; secondly, forming a first element; and finally, one or more junction boxes needing to be installed meet the first element and the second element of the corresponding requirements one by one, and are transferred and positioned on the transfer platform through the same mechanical arm, so that feeding of the junction boxes to be installed of the single photovoltaic module is completed. On the basis of visual detection and combination of the first element and the second element, the junction box can be taken out at will to implement disordered automatic feeding of the junction box, meanwhile, transmission of the annular transmission belt and overturning of the overturning platform at different angles are fully utilized, homeopathic overturning or homeopathic unloading is achieved in a narrow space by means of the transmission speed difference, impact on the junction box is small, and the working efficiency is high. And in addition, at least one side can be used as a reference in the unloading process, and clamping is convenient.

Description

[0001] This application is a divisional application with a filing date of June 7, 2024, application number 2024107338830, and name: Automatic assembly process for photovoltaic module junction boxes. Technical Field

[0002] The invention belongs to the technical field of photovoltaics, and in particular relates to a feeding method for a photovoltaic component junction box. Background Art

[0003] Conventional photovoltaic modules (single glass or double glass) include an upper glass cover plate, solar cells, a lower base plate, and a junction box installed on the upper glass cover plate, which are arranged in order from top to bottom. The junction box includes a coil, a box body and a connector located on opposite sides of the coil and extending in the same direction. That is to say, in the process of loading, it not only has a positive and negative difference (box body), but also has position angle requirements (whether the coil faces left or right). Therefore, there are the following technical difficulties in actual processing:

[0004] 1) The wiring box needs to be sorted in an orderly manner during loading, which requires not only multiple visual inspections but also selection. Therefore, not only is the operation cumbersome, but there is also a probability of material breakage, which leads to interruption of the operation and affects the overall assembly efficiency;

[0005] 2) If you want to flip the junction box, you need to use a unique flipping mechanism, which not only requires a large operating space, but also once it acts on different positions, the junction boxes unloaded onto the conveyor belt have different positions and angles, which is not easy to clamp later. At the same time, once there is a visual misjudgment or selection accident, the supplied junction boxes are directly returned, resulting in an interruption in the supply of junction boxes and a high downtime rate;

[0006] 3) Once two or more junction boxes need to be installed on the same photovoltaic module, they are generally assembled one by one due to the difficulty of feeding materials. As a result, the assembly efficiency is low. At the same time, in the front and back assembly process of the same photovoltaic module, there are not only front and back interferences or assembly obstacles, but also the uniformity or alignment of the installation quality is difficult to meet the requirements due to different installation conditions. Summary of the invention

[0007] The technical problem to be solved by the present invention is to overcome the deficiencies of the prior art and provide a new feeding method for a photovoltaic module junction box.

[0008] In order to solve the above technical problems, the present invention adopts the following technical solutions: a feeding method for a photovoltaic module junction box, wherein the feeding device adopted by the feeding device includes a supply unit and a material taking unit, wherein the supply unit can supply the junction boxes to the flip platform one by one and continuously, and includes a material frame component and a feeding robot, wherein the flip platform is flipped around the horizontal direction by a flip component; the material taking unit includes an endless conveyor belt located below the flip platform, a manipulator for grabbing the junction box from the endless conveyor belt, a visual detection component located above the flip platform and the endless conveyor belt, and a central control adjustment component, and the feeding method includes the following steps:

[0009] First, the junction boxes are taken out one by one and randomly from the material frame, and the junction boxes are laid on the flipping platform, wherein the junction boxes include a coil, a box body and a connector located on opposite sides of the coil and extending in the same direction; secondly, based on the vision of the visual detection component, the front and back information of the junction box on the flipping platform is obtained, and the flipping platform is controlled to flip in a horizontal direction so that the front and back directions of the junction box remain unchanged and gradually approach the circular conveyor belt based on one side of the junction box or the transmission speed difference formed by the flipping platform and the circular conveyor belt cooperates to gradually approach the circular conveyor belt based on one side so that the front and back of the junction box are flipped 180 degrees and then unloaded onto the circular conveyor belt, so that the junction box The first element is that the front and back orientations match the orientation required for loading. Next, the left and right orientation information of the coil on the circular conveyor belt is obtained visually, and the robot clamps the junction box with adaptive angle adjustment on the circular conveyor belt that meets the first element, and keeps the left and right orientation unchanged or flips the left and right orientation 180 degrees to unload it to the transfer platform, so that the left and right orientation of the coil of the junction box matches the orientation required for loading, which constitutes the second element. Finally, one or more junction boxes that need to be installed meet the corresponding requirements of the first and second elements one by one, and are transferred and positioned on the transfer platform by the same robot to complete the loading of the junction box to be installed of a single photovoltaic module.

[0010] According to a specific implementation and preferred aspect of the present invention, when the first element is met, when the angle formed by the flip platform and the horizontal plane is less than or equal to 30°, the junction box is unloaded to the endless conveyor belt in the current state. Under the small angle unloading, the junction box slides freely to the endless conveyor belt.

[0011] According to another specific implementation and preferred aspect of the present invention, when the first element is met, when the angle formed by the flip platform and the horizontal plane is a right angle or an obtuse angle, the junction box is flipped 180° in the cooperation of flipping and moving forward and is transferred forward along the endless conveyor. When the flip angle is a right angle or an obtuse angle, there is a cooperation between the sliding process and the moving process, and the positive and negative flipping is formed by taking advantage of the momentum. Of course, the so-called right angle or obtuse angle is preferably an obtuse angle (generally within 120°), because there is a forward push on the product, which is more conducive to flipping, and when the angle formed by the flip platform and the horizontal plane is an obtuse angle, the junction box fits the flip platform and falls freely and keeps the forward flipping trend to be unloaded on the endless conveyor. In short, this is not a throwing method, but a flipping method using momentum (not only does it require a small space, but it is also easy to control according to the flipping angle, and it goes with the flow and is very reasonable). Of course, there is another way to implement it, which is to flip it over. That is to say, the junction box is flipped forward by the flipping platform and flipped in the air before falling onto the circular conveyor belt (this method seems feasible, but the success rate of the flip is difficult to control, and there is a collision between the internal components of the junction box, and a larger space is required).

[0012] In some specific embodiments, the flip platform is installed at the rear end of the endless conveyor belt; in the initial state, the flip platform is parallel to the surface of the endless conveyor belt and forms a height difference. In this way, there is space for flipping, and the flip platform is rotatably arranged on the corresponding frame through a flip shaft extending along the width direction of the endless conveyor belt, and the flip component is a power component that drives the flip shaft to rotate. Conventional flip components can adopt a flip motor (motor) and a pulley drive mode, and of course can also be directly driven by a motor.

[0013] According to another specific implementation and preferred aspect of the present invention, the transmission speed formed by the endless conveyor belt is less than the speed at which the junction box is unloaded from the flipping platform. Under the control of this speed difference, the success rate of the junction box flipping is increased, mainly because once the flip contact moment, if the forward speed is too fast, it will cause the product to fall backwards, therefore, the success rate of the flipping can be further improved and the probability of feeding interruption can be reduced.

[0014] According to another specific implementation and preferred aspect of the present invention, when the second element is met, the manipulator used has an adaptive clamping mode and a flipping and turning mode, wherein when picking up materials from the ring conveyor belt, the terminal box is clamped by adaptively changing the angle in combination with visual information; after clamping, the flipping and turning mode is selected according to the left and right orientation information of the coil, and the current angle is maintained or a 180° turn is made to match the terminal box with the feeding orientation. In short, this manipulator increases the practicality of the manipulator and further facilitates clamping by freely switching between the adaptive clamping mode and the flipping and turning mode.

[0015] According to another specific implementation and preferred aspect of the present invention, the material frame uses a robot and layered circulation feeders formed on both sides of the robot to implement automatic filling of the material frame supply. In this way, the material supply of the junction box can be completed without interruption. At the same time, the material frame inlet and the material frame outlet of each layered circulation feeder are located on the same side and both emerge from the corresponding side of the rack. Such a layout is not only convenient for the supply operation of the material frame, but also convenient for users to supplement or recycle the material frame.

[0016] Furthermore, each layered cyclic feeding includes a feeding auxiliary station, a loading station, a discharging station, a discharging auxiliary station, and a monitoring station, wherein the loading station and the discharging station are arranged up and down, and under the status monitoring of the monitoring station, the loading station can move up and down to relatively connect the feeding auxiliary station and the discharging auxiliary station, and after the loading station is empty, the feeding auxiliary station automatically supplies the material frame to the loading station. Not only can the material frame be cyclically supplied, but the probability of the junction box being cut off is also low.

[0017] Preferably, at least one loading station is kept above the unloading station in each layered cyclic feeding. In short, at least one of the loading stations keeps the material frame supplied normally, further reducing the interruption rate of the material frame supply.

[0018] In addition, the material picking unit also includes a return hopper formed at the front end of the circular conveyor belt, and a return box located at the bottom of the return hopper and connected to the return hopper. When the first element is formed, the junction box with mismatched orientation returns and circulates the material from the output end of the circular conveyor belt.

[0019] Due to the implementation of the above technical solution, the present invention has the following advantages compared with the prior art:

[0020] In the existing junction box assembly and feeding process, the junction box loading needs to be orderly sorted, which requires not only multiple visual inspections but also selection. Therefore, not only is the operation cumbersome, but there is also a probability of material breakage, resulting in operation interruption, affecting the overall assembly efficiency; at the same time, if the junction box is to be flipped, a unique flipping mechanism is required, which not only requires a large operating space, but also once it acts at different positions, the position angles of the junction boxes unloaded onto the conveyor belt are different, which is not easy for subsequent clamping operations. At the same time, once a visual misjudgment or selection accident occurs, the supplied junction boxes are directly returned, resulting in an interruption in the supply of junction boxes, resulting in a high downtime rate and other shortcomings. The present invention cleverly solves the various existing deficiencies through the overall design of the automatic assembly process of photovoltaic module junction boxes. After adopting the feeding method of the photovoltaic module junction box, first, the junction boxes are taken out one by one from the material frame, and the junction boxes are laid flat on the flip platform; secondly, based on the vision, the front and back information of the junction box on the flip platform is obtained, and the flip platform is controlled to flip so that the front and back directions of the junction box remain unchanged or flip 180 degrees to unload it onto the circular conveyor belt, so that the front and back sides of the junction box match the required orientation for loading to constitute the first element; then, the left and right orientation information of the coil on the circular conveyor belt is obtained by vision, and the robot clamps the junction box with adaptive angle adjustment on the circular conveyor belt that meets the first element, and keeps the angle unchanged or flips 180 degrees to unload it to the transfer platform, so that the left and right orientation of the coil of the junction box matches the orientation for loading The need for orientation matching constitutes the second element. Finally, the one or more junction boxes that need to be installed will meet the first element and the second element one by one, and will be transferred and positioned on the transfer platform by the same manipulator to complete the loading of the junction box to be installed of a single photovoltaic module. Therefore, the present invention is based on visual detection and the combination of the first element and the second element. It can not only take out the junction box at will to implement disorderly automatic loading of the junction box, but also, even if a flipping error occurs, it can make full use of the transmission of the circular conveyor belt and the different angles of the flipping platform. In a small space, the transmission speed difference is used to flip or unload the junction box, which has little impact on the junction box itself, and at least one side can be used as a reference during unloading to facilitate subsequent clamping. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 This is a schematic diagram of the structure of the integrated machine for loading, gluing and assembling the junction box of a photovoltaic module in this embodiment;

[0022] Figure 2 for Figure 1 The structural diagram of the supply unit;

[0023] Figure 3 for Figure 2 A simplified schematic diagram of the structure;

[0024] Figure 4 for Figure 1A partially omitted schematic diagram (excluding the supply unit);

[0025] Figure 5 for Figure 4 The structural diagram of the middle take-away unit;

[0026] Figure 6 for Figure 5 Another perspective structural diagram of;

[0027] Figure 7 for Figure 5 A simplified schematic diagram of

[0028] Figure 8 for Figure 4 Schematic diagram of gluing and assembly structure;

[0029] Fig. 9 for Figure 8 A magnified schematic diagram of the assembly structure;

[0030] Fig.10 for Figure 8 A magnified schematic diagram of the middle glue-applying structure;

[0031] Among them: 1, rack; 2, loading device; 20, supply unit; 200, material frame assembly; s1, first conveyor belt; s2, second conveyor belt; s3, third conveyor belt; s4, elevator; s5, interval sensor; s6, material frame monitor; q, material frame; 201, feeding robot; 21, material picking unit; 210, circular conveyor belt; 211, manipulator; a, gripper; b, power device; c, adjustment motor; 212, visual detection component; x, visual camera; 213, return hopper; 214, return box; 215, vibrator; 216, guardrail;

[0032] 3. Gluing device; 30. Temporary storage platform for glue heads; k. Mounting hole; 31. Gluing head;

[0033] 4. Assembling device; 40. Box body clamp; 41. Coil clamp; 42. Curing assembly;

[0034] 5. Flipping parts; f. Flipping axis;

[0035] 6. Arrange components;

[0036] H, junction box; h1, coil; h2, box body; h3, connector.

[0037] G, turning platform; M, transfer platform; J, truss. DETAILED DESCRIPTION

[0038] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, the present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. In the following description, many specific details are set forth to facilitate a full understanding of the present invention. However, the present invention can be implemented in many other ways different from those described herein, and those skilled in the art can make similar improvements without violating the connotation of the present invention, so the present invention is not limited by the specific embodiments disclosed below.

[0039] In the description of the present invention, it is to be understood that the terms “center”, “longitudinal”, “lateral”, “length”, “width”, “thickness”, “up”, “down”, “front”, “back”, “left”, “right”, “vertical”, “horizontal”, “top”, “bottom”, “inside”, “outside”, “clockwise”, “counterclockwise”, “axial”, “radial”, “circumferential”, etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0040] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In the description of the present invention, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0041] In the present invention, unless otherwise clearly defined and specified, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be directly connected, or indirectly connected through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0042] In the invention, unless otherwise clearly specified and limited, a first feature being “above” or “below” a second feature may mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediate medium. Moreover, a first feature being “above”, “above”, or “above” a second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. A first feature being “below”, “below”, or “below” a second feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0043] It should be noted that when an element is referred to as being "fixed to" or "disposed on" another element, it may be directly on the other element or there may be a central element. When an element is considered to be "connected to" another element, it may be directly connected to the other element or there may be a central element at the same time. The terms "vertical", "horizontal", "upper", "lower", "left", "right" and similar expressions used herein are for illustrative purposes only and do not represent the only implementation method.

[0044] like Figures 1 to 10 As shown, the automatic assembly process of the photovoltaic module junction box of this embodiment, which adopts the photovoltaic module junction box loading, gluing and assembly integrated machine includes a frame 1, a loading device 2, a gluing device 3 and an assembly device 4. Specifically, the junction box H includes a coil h1, a box body h2 located on opposite sides of the coil h1 and extending in the same direction, and a connector h3, wherein the box body h2 itself has a front and back installation side, and the coil h1 has a left and right direction. Therefore, a special loading device 2 is required for disordered loading.

[0045] Specifically, the loading device 2 transfers the junction boxes H one by one from the turning platform G to the transfer platform M, and the loading device 2 includes a supply unit 20 and a material taking unit 21, the supply unit 20 can supply the junction boxes H to the turning platform G one by one and continuously, wherein the turning platform G is turned around the horizontal direction by the turning component 5, and the turning platform G has an initial state and a turning state, when in the initial state, the turning platform G is horizontally arranged; when in the turning state, the turning platform G is intersecting with the horizontal plane; the material taking unit 21 includes an endless conveyor belt 210 located below the turning platform G, a manipulator 211 for grabbing the junction box from the endless conveyor belt 210, a visual detection component 212 located above the turning platform G and the endless conveyor belt 210, and a return hopper 213 formed at the front end of the endless conveyor belt 210. , a return box 214 located at the bottom of the return hopper 213 and connected to the return hopper 213, and a central control adjustment component, wherein the annular conveyor belt 210 and the flipping platform G have the same flipping and feeding direction and form a movement collaboration, the central control adjustment component is connected with the visual detection component 212, the flipping component 5, and the manipulator 211, and based on the information obtained by the visual detection component 212, the flipping movement of the flipping component 5 drives the junction box H to maintain the current state and unload to the annular conveyor belt 210, or drives the junction box H to gradually approach the annular conveyor belt to form a flipping and forward collaboration to adjust the junction box 180° on the front and back sides; the manipulator 211 maintains the current state and clamps the junction box H from the annular conveyor belt 210 to the transfer platform M, or the manipulator 211 clamps it and adjusts the direction 180° before transferring it to the transfer platform M.

[0046] In some specific embodiments, the supply unit 20 includes a material frame assembly 200 that can continuously supply and load junction boxes H and can automatically fill positions, and a feeding robot 201, wherein the material frame assembly 200 forms a loading station and an auxiliary station, and the auxiliary station can automatically supply material frames and recycle material frames to the loading station, and the feeding robot 201 takes out the junction boxes H one by one from the loading station and transfers them to the turning platform G. In this way, the probability of interruption of feeding is reduced by cyclically supplying the material frame.

[0047] Specifically, the material frame assembly 200 includes a first conveyor belt s1 and a second conveyor belt s2 arranged in layers, and a third conveyor belt s3 located at the same end of the first conveyor belt s1 and the second conveyor belt s2 and capable of being lifted up and down, wherein the first conveyor belt s1 and the second conveyor belt s2 each have two temporary storage stations (of course, more are also possible), and the two temporary storage stations of each conveyor belt can be separated by a barrier, and there is only one station on the third conveyor belt s3 (only one material frame can be placed), and when the third conveyor belt s3 is lifted up and down, the first conveyor belt s1 and the third conveyor belt s3 or the second conveyor belt s2 and the third conveyor belt s3 are connected to automatically fill in or unload the material frame; and the upper position of the third conveyor belt s3 is the feeding station, and the other positions are auxiliary material stations. The layout is made in a motion connection manner, which not only makes the entire feeding structure simple and occupies less space; but also facilitates the circulation of the material frame itself (feeding and discharging). The auxiliary material station includes a feeding auxiliary station, a discharging auxiliary station, and a discharge auxiliary station, wherein the loading station is located directly above the discharge auxiliary station, the first conveyor belt s1 constitutes the feeding auxiliary station, and the second conveyor belt s2 constitutes the discharge auxiliary station. In short, by switching the position of the third conveyor belt s3 between the discharge auxiliary station and the feeding station, the feeding auxiliary station and the discharge auxiliary station can be connected to form a material frame circulation supply mode, and it is also convenient for the junction box to take the material. At the same time, for the lifting and lowering of the third conveyor belt s3, a conventional hoist s4 can be used, but in order to accurately control the material frame filling, an interval sensor s5 needs to be set to separate and transmit the material frame q in each auxiliary station. The specific hoist s4 is a slide rail wire, and is in the form of a transmission screw to lift up and down; the interval sensor s5 uses a retractable cylinder to separate, and needs to be intercepted or released to perform the material frame filling operation.

[0048] In this example, there are two groups of material frame assemblies 200, which are formed on the opposite sides of the feeding robot 201, wherein at least one third conveyor belt s3 is kept in the feeding station in the two groups of material frame assemblies 200. Here, it can at least be guaranteed that there will be no interruption in the material picking of the material picking manipulator, ensuring continuous operation. At the same time, the two groups of material frame assemblies 200 are symmetrically arranged, and the first conveyor belt s1 and the second conveyor belt s2 are away from the end of the third conveyor belt s3. The end-emerging arrangement facilitates the feeding and recycling connection operations of the material frame. At the same time, a material frame monitor s6 is also provided above each feeding station, wherein the material frame monitor s6 assists the feeding robot 201 in picking up materials, and when the material frame q is emptied, the material frame q is automatically unloaded and the material is replenished.

[0049] In this example, the flip platform G is installed at the rear end of the circular conveyor 210. When in the initial state, the flip platform G is parallel to the surface of the circular conveyor 210 and forms a height difference. In this way, there is space for flipping, and the flip platform is rotated on the corresponding frame through the flip axis extending along the width direction of the circular conveyor, and the flip component 5 is a power component that drives the flip axis f to rotate. Conventional flip components can adopt a flip motor (motor) and a pulley transmission method, and of course can also be directly driven by a motor. At the same time, when the angle formed by the flip platform G and the horizontal plane is less than or equal to 30°, the junction box H maintains the current state and is unloaded to the circular conveyor 210; when the angle formed by the flip platform G and the horizontal plane is an obtuse angle, the junction box H is adjusted 180° on the front and back sides in the cooperation of flipping and moving forward and is transferred forward with the circular conveyor 210. Under the unloading of small-angle dumping, the junction box slides freely onto the circular conveyor belt; when the flipping angle is a right angle or an obtuse angle, there is a cooperation between the sliding process and the forward process, and the momentum is used to form a positive and negative flip. An obtuse angle (generally within 120°) is preferred because it pushes the product forward and is more conducive to flipping. In short, this is not a throwing method, but a flipping method using momentum (not only does it require a small space, but it is also easy to control according to the flipping angle, and it is very reasonable to go with the flow). Of course, there is another implementation method, which is flipping. That is, the junction box is flipped forward by the flipping platform and flipped in the air before falling onto the circular conveyor belt (this method is feasible on the surface, but the success rate of flipping is difficult to control, and there is a collision of internal components of the junction box, and it requires more space). In this example, the transmission speed formed by the circular conveyor belt 210 is less than the speed at which the junction box H is unloaded from the flipping platform G. Under the control of this speed difference, the success rate of the junction box flipping is increased. The reason is that once the flipping contact is reached, if the forward speed is too fast, the product will fall backwards. Therefore, the success rate of the flipping can be further improved and the probability of feeding interruption can be reduced.

[0050] In some specific embodiments, the manipulator 211 includes a clamping jaw a matching the box body h2, a power device b driving the clamping jaw a to clamp or open, and an adjustment motor c driving the clamping jaw a and the power device b to rotate together in a vertical direction, wherein the adjustment motor c has a coil orientation rotation mode and a box body adaptive angle clamping mode, when the box body h2 is clamped, the adjustment motor c selects the adaptive angle clamping mode to clamp the box body h2; when the box body h2 is clamped, if the coil h1 is in the opposite direction, the adjustment motor c switches the coil orientation rotation mode and uses 180° as a rotation cycle to make the coil h1 of the junction box H match the feeding direction. The visual detection component 212 includes a visual camera x and an image processor located at the top of the corresponding rack, wherein the visual camera x obtains photo information, and the image processor analyzes the front and back directions of the junction box and the coil orientation information in the picture, and controls the flipping component 5 and the manipulator 211 to move. At the same time, the visual inspection component 212 obtains the front and back information of the junction box on the endless conveyor belt 210, and directly sends the junction box H opposite to the requirement forward into the return hopper 213 and falls into the return box 214. Specifically, the return hopper 213 is tilted up and down, and the upper end is located in front of the output end of the endless conveyor belt 210, and the lower end extends to the bottom of the endless conveyor belt 210 and docks with the return box 214. Preferably, the return hopper 213 is arranged close to the endless conveyor belt, and the angle formed with the conveying surface of the endless conveyor belt is less than 30°. Avoid the existence of excessively high drop and reduce the impact damage rate in the return of mismatched junction boxes. Furthermore, a vibrator 215 is also provided on the return hopper 213, wherein the vibrator increases the smoothness of the return material. Guardrails 216 are also provided on the opposite sides of the flip platform G, and the guardrails 216 extend to the upper side of the endless conveyor belt 210.

[0051] In addition, there are two positioning centers on the transfer platform M, and there are two groups of feeding devices, which are symmetrically distributed. The front and back sides of the junction boxes provided by the two groups of feeding devices are consistent, and the coils are in opposite directions, so as to meet the needs of synchronous installation of multiple junction boxes on a photovoltaic module and improve installation efficiency. Then, a positioning center based on the junction box H is formed on the transfer platform M, and the feeding device also includes a straightening component 6 set at the positioning center for clamping and correcting deviation. The position of the junction box is uniformly adjusted under the straightening component 6 for accurate installation. Specifically, the straightening component 6 is a positioning clamp set on the opposite sides of the positioning center and clamped in relative motion.

[0052] See again Figures 8 to 10, the gluing device 3 and the assembling device 4 are installed on the same truss J, and are distributed on opposite sides of the truss J. In short, the relative combination of functional modules is realized, which not only reduces the overall volume of the integrated machine, but also makes the actual operation more convenient. In some specific embodiments, the gluing device 3 includes a temporary storage platform 30 for the gluing head and a gluing head 31, wherein a mounting hole k is formed on the temporary storage platform 30 for the gluing head, and when not working, the gluing head 31 is inserted into the mounting hole k (generally, the mounting hole is filled with silicone oil, which has the effect of dissolving and volatilizing glue, and the silicone oil will not affect the subsequent gluing, and the uniformity of the gluing is controlled and adjusted by the valve of the gluing equipment). The assembling device 4 includes a box body clamp 40, a coil clamp 41, and a curing assembly 42, wherein under the curing conditions provided by the curing assembly 42, the box body clamp 40 fits the mounting surface of the box body h2 onto the photovoltaic assembly. In some specific embodiments, when the glue applied is UV glue, the curing component 42 used is conventional light beam curing; when the glue applied is AB glue, the curing component 42 is a visual camera and a fill light tool, that is, two photos are taken before and after gluing. The photo before gluing is taken to see whether there is any deviation in the angle of the busbar axis direction. If there is a deviation, the gluing position of the glue head is adjusted to compensate for the deviation; the second photo is taken after gluing and installing the junction box, which mainly serves the purpose of re-inspection after installation.

[0053] In summary, the automatic assembly process of the photovoltaic module junction box includes the following steps:

[0054] S1, automatic feeding of junction box

[0055] First, the junction boxes are taken out one by one and arbitrarily from the material frame, and the junction boxes are laid on the flipping platform, wherein the junction boxes include a coil, a box body and a connector located on opposite sides of the coil and extending in the same direction; secondly, the front and back information of the junction box on the flipping platform is obtained based on vision, and the flipping platform is controlled to flip in a horizontal direction so that the front and back directions of the junction box remain unchanged and gradually approach the circular conveyor belt based on one side of the junction box or the transmission speed difference formed by the flipping platform and the circular conveyor belt cooperates to gradually approach the circular conveyor belt based on one side so that the front and back of the junction box are flipped 180 degrees and then unloaded onto the circular conveyor belt, so that the front and back directions of the junction box match the direction required for loading, forming the first The first element is that the junction boxes with mismatched orientations are recycled and circulated from the output end of the circular conveyor belt; then, the left-right orientation information of the coil on the circular conveyor belt is obtained by vision, and the robot clamps the junction box with adaptive angle adjustment from the circular conveyor belt that meets the first element, and unloads it to the transfer platform with the left-right orientation maintained at an unchanged angle or flipped 180 degrees from left to right, so that the left-right orientation of the coil of the junction box matches the orientation required for loading, which constitutes the second element. Finally, one or more junction boxes that need to be installed meet the first and second elements of the corresponding requirements one by one, and are transferred and positioned on the transfer platform by the same robot to complete the loading of the junction box to be installed of a single photovoltaic module;

[0056] S2. Loading and gluing of photovoltaic modules

[0057] During the loading process of the junction box, the photovoltaic module is horizontally fed into the assembly station with the glass surface facing upward, and the glue head simultaneously glues multiple junction box installation positions to form a glue frame;

[0058] S3. Assembly of junction box

[0059] A transfer robot is used to take out all the junction boxes from the transfer platform and transfer them to the gluing area. The joint surfaces of each junction box are glued to the glue frame of the photovoltaic module. The gluing is completed with the correction of auxiliary tools or light beam curing. Then the photovoltaic module is moved horizontally out of the assembly station.

[0060] Specifically, when the first element of S1 is met, when the angle formed by the flip platform and the horizontal plane is less than or equal to 30°, the junction box maintains the current state and is unloaded to the circular conveyor. Under small-angle unloading, the junction box slides freely onto the circular conveyor. When the angle formed by the flip platform and the horizontal plane is a right angle or an obtuse angle, the junction box is adjusted 180° front and back in the cooperation of flipping and moving forward and is transferred forward with the circular conveyor. When the flip angle is a right angle or an obtuse angle, there is a cooperation between the sliding process and the forward process, and the front and back flip is formed by taking advantage of the momentum. Of course, the so-called right angle or obtuse angle is preferably an obtuse angle (generally within 120°), because there is a forward push on the product, which is more conducive to flipping, and when the angle formed by the flip platform and the horizontal plane is an obtuse angle, the junction box fits the flip platform and falls freely and maintains a forward flipping trend to be unloaded on the circular conveyor. In short, this is not a throwing method, but a flipping method using momentum (not only does it require a small space, but it is also easy to control according to the flipping angle, and it goes with the flow, which is very reasonable). Of course, there is another implementation method, which is flipping, that is, the junction box is flipped forward by the flipping platform and flipped in the air before falling onto the circular conveyor belt (this method is feasible on the surface, but the success rate of flipping is difficult to control, and there is a collision of internal components of the junction box, and it requires more space). In some specific embodiments, the flipping platform is installed at the rear end of the circular conveyor belt; when in the initial state, the flipping platform is parallel to the surface of the circular conveyor belt and forms a height difference. In this way, there is space to flip, and the flipping platform is rotated on the corresponding frame through the flipping shaft extending along the width direction of the circular conveyor belt, and the flipping component is a power component that drives the flipping shaft to rotate. Conventional flipping components can use a flipping motor (motor) and a pulley drive method, and of course they can also be directly driven by a motor. When the second element of S1 is met, the robot used has an adaptive clamping mode and a flipping and turning mode. When picking up materials from the circular conveyor belt, the terminal box is clamped by adaptively changing the angle in combination with visual information. After clamping, the flipping and turning mode is selected according to the left and right orientation information of the coil, and the current angle is maintained or a 180° turn is made to match the terminal box with the feeding orientation. The practicality of the robot is increased, and clamping is further facilitated. In addition, in S1, a reorganization clamp is also provided on the transfer platform, in which each terminal box is positioned at the positioning center from the box body, and the reorganization clamp is used to clamp and align the two sides of the box body. The alignment operation is performed before installation to improve assembly accuracy.

[0061] In summary, after adopting the automatic assembly process of photovoltaic module junction boxes, first, the junction boxes are taken out one by one from the material frame, and the junction boxes are laid flat on the flip platform; secondly, based on the vision, the front and back information of the junction box on the flip platform is obtained, and the flip platform is controlled to flip so that the direction of the junction box remains unchanged or flipped 180 degrees to unload it onto the circular conveyor belt, so that the front and back sides of the junction box match the required orientation for loading to form the first element, and the unmatched junction boxes are returned; then, the left and right orientation information of the coil on the circular conveyor belt is obtained by vision, and the robot clamps the junction box with adaptive angle adjustment on the circular conveyor belt that meets the first element, and keeps the angle unchanged or flips 180 degrees to unload it to the transfer platform, so that the left and right orientation of the coil of the junction box is consistent with the upper The required orientation matching of the materials constitutes the second element. Finally, one or more junction boxes that need to be installed meet the first and second elements one by one, and are transferred and positioned on the transfer platform by the same robot to complete the loading of the junction boxes to be installed of a single photovoltaic module. At the same time, during the loading process of the junction boxes, the photovoltaic modules are horizontally sent to the assembly station with the glass surface facing up, and the corresponding glue heads are synchronously glued to multiple junction box installation positions. Then, the transfer robot is used to take out all the junction boxes from the transfer platform, and at the same time, they are transferred to the glue area, and the joint surfaces of each junction box are glued to the surface layer of the photovoltaic module. Then, the assembled photovoltaic modules are horizontally moved out of the assembly station. Therefore, the present invention is based on visual detection and combines the first and second elements. Not only can the junction box be taken out at will to implement disorderly automatic loading of the junction box, but even if a flipping error occurs, the material return operation can be performed, so that the junction box can be continuously supplied and the probability of material breakage is low, thereby improving assembly efficiency. At the same time, the transmission of the ring conveyor belt and the flipping of the flipping platform are fully utilized. In a small space, the transmission speed difference is used to flip or unload the junction box, which has little impact on the junction box itself, and at least one side can be used as a reference during unloading, which is convenient for subsequent clamping. On the other hand, on the same photovoltaic module, the loading, gluing and assembly of multiple junction boxes are implemented simultaneously, which not only increases the assembly efficiency, but also balances the assembly quality. In addition, there is no interference or obstruction to the assembly, which is convenient for operation. The gluing device and assembly adopted in the third aspect The device is installed on the same truss, which not only reduces the overall volume of the integrated machine, but also makes the actual operation more convenient. At the same time, the box body and the coil are synchronously clamped in combination with curing to implement high-quality gluing and assembly. In addition, silicone oil is used to seal the glue head, because silicone oil has the effect of dissolving and volatilizing glue, and silicone oil will not affect the subsequent gluing; the fourth aspect is to use the motion connection method for layout, which not only makes the entire feeding structure simple and occupies a small space; but also is conducive to the circulation of the material frame itself (feeding and discharging). At the same time, the third conveyor belt switches between the unloading auxiliary station and the feeding station, so that the feeding auxiliary station and the discharging auxiliary station can be connected, forming a material frame circulation supply mode, and it is also convenient for the junction box to take materials uninterruptedly;The fifth aspect is that the material frame assembly has two groups, and they are formed on the opposite sides of the material picking robot, wherein at least one third conveyor belt is maintained at the feeding station in the two groups of material frame supply units, thereby at least ensuring that the material picking of the material picking robot will not be interrupted, ensuring continuous operation, and at the same time, the end portion is provided to facilitate the feeding and recovery connection operations of the material frame; the sixth aspect is that the transmission speed formed by the annular conveyor belt is less than the speed at which the junction box is unloaded from the flipping platform. Under the control of this speed difference, the success rate of the flipping of the junction box is increased, mainly because once the flipping contact occurs, if the forward speed is too fast, it will cause the product to tip backwards, so it can be carried out. The success rate of flipping is improved in one step, and the probability of feeding interruption is reduced; the seventh aspect is that the return hopper is set close to the circular conveyor belt, and the angle formed between it and the conveying surface of the circular conveyor belt is less than 30°, avoiding excessive drop and reducing the collision damage rate of the return material of the mismatched junction box. At the same time, a vibrator is also provided on the return hopper, and the vibrator increases the smoothness of the return material; the eighth aspect is to make full use of the characteristics of the transfer manipulator and adjust the direction of the coil to form the necessary conditions for disordered loading. At the same time, the positioning clamping can maintain a relatively accurate position for the next step of assembly of the junction box, and the guardrail is used for transmission protection during loading and unloading, which is safer. ;

[0062] The above detailed description of the present invention is intended to enable persons familiar with the art to understand the contents of the present invention and implement them. It does not limit the protection scope of the present invention. Any equivalent changes or modifications made according to the spirit of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for feeding a photovoltaic module junction box, characterized in that: The feeding device used includes a supply unit and a pick-up unit. The supply unit can supply junction boxes to the flip platform one by one and continuously, and includes a material frame component and a feeding robot. The flip platform is flipped around the horizontal direction by a flip component. The pick-up unit includes an endless conveyor belt located below the flip platform, a manipulator for grabbing the junction box from the endless conveyor belt, a visual detection component located above the flip platform and the endless conveyor belt, and a central control adjustment component. The feeding method includes the following steps: First, the junction boxes are taken out one by one and randomly from the material frame, and the junction boxes are laid on the flipping platform, wherein the junction boxes include a coil, a box body and a connector located on opposite sides of the coil and extending in the same direction; secondly, based on the vision of the visual detection component, the front and back information of the junction box on the flipping platform is obtained, and the flipping platform is controlled to flip in a horizontal direction so that the front and back directions of the junction box remain unchanged and gradually approach the circular conveyor belt based on one side of the junction box or the transmission speed difference formed by the flipping platform and the circular conveyor belt cooperates to gradually approach the circular conveyor belt based on one side so that the front and back of the junction box are flipped 180 degrees and then unloaded onto the circular conveyor belt, so that the junction box The first element is that the front and back orientations match the orientation required for loading. Next, the left and right orientation information of the coil on the circular conveyor belt is obtained visually, and the robot clamps the junction box with adaptive angle adjustment on the circular conveyor belt that meets the first element, and keeps the left and right orientation unchanged or flips the left and right orientation 180 degrees to unload it to the transfer platform, so that the left and right orientation of the coil of the junction box matches the orientation required for loading, which constitutes the second element. Finally, one or more junction boxes that need to be installed meet the corresponding requirements of the first and second elements one by one, and are transferred and positioned on the transfer platform by the same robot to complete the loading of the junction box to be installed of a single photovoltaic module.

2. The method for feeding a photovoltaic module junction box according to claim 1, characterized in that: When the first element is met, when the angle formed by the turning platform and the horizontal plane is less than or equal to 30°, the junction box remains in the current state and is unloaded to the endless conveyor belt.

3. The method for feeding a photovoltaic module junction box according to claim 1, characterized in that: When the first element is met, when the angle formed by the flipping platform and the horizontal plane is a right angle or an obtuse angle, the junction box is flipped 180° on the front and back in the cooperation of flipping and moving forward and is transferred forward along the circular conveyor belt.

4. The method for feeding a photovoltaic module junction box according to claim 1, characterized in that: The transmission speed formed by the endless conveyor belt is less than the speed at which the junction box is unloaded from the turning platform.

5. The method for feeding a photovoltaic module junction box according to claim 1, characterized in that: The flipping platform is installed at the rear end of the circular conveyor belt; in the initial state, the flipping platform is parallel to the surface of the circular conveyor belt and forms a height difference; the flipping platform is rotatably arranged on the corresponding frame through a flipping axis extending along the width direction of the circular conveyor belt, and the flipping component is a power component that drives the flipping axis to rotate.

6. The method for feeding a photovoltaic module junction box according to claim 1, characterized in that: When the second element is met, the robot used has an adaptive clamping mode and a flipping and turning mode. When picking up materials from the ring conveyor belt, the junction box is clamped by adaptively changing the angle in combination with visual information. After clamping is completed, select the flipping direction mode according to the left and right orientation information of the coil, maintain the current angle or turn 180° to match the junction box with the feeding direction.

7. The method for feeding a photovoltaic module junction box according to claim 1, characterized in that: The material frame adopts a robot and layered circulation feeders formed on both sides of the robot to implement automatic filling of the material frame supply, wherein the material frame inlet and the material frame outlet of each layered circulation feeder are located on the same side and both emerge from the corresponding rack side.

8. The method for feeding a photovoltaic module junction box according to claim 7, characterized in that: Each layered cyclic feeding includes a feeding auxiliary station, a loading station, an unloading station, an unloading auxiliary station, and a monitoring station, wherein the loading station and the unloading station are arranged up and down, and under the status monitoring of the monitoring station, the loading station can move up and down to relatively connect the feeding auxiliary station and the unloading auxiliary station, and after the loading station is unloaded, the feeding auxiliary station automatically supplies the material frame to the loading station.

9. The method for feeding a photovoltaic module junction box according to claim 8, characterized in that: In each layered cyclic feeding, at least one loading station is maintained above the unloading station.

10. The method for feeding a photovoltaic module junction box according to any one of claims 1 to 9, characterized in that: The material taking unit also includes a return hopper formed at the front end of the circular conveyor belt, and a return box located at the bottom of the return hopper and connected to the return hopper. When the first element is formed, the junction box with mismatched orientation returns and circulates the material from the output end of the circular conveyor belt.

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