Photovoltaic module junction box installation machine and installation method suitable for disorderly grabbing

Abstract

The present invention discloses a photovoltaic module junction box installation machine suitable for disorderly grabbing. It is based on an integrally assembled main frame, auxiliary frame and gantry hanger, and is provided with a storage unit, disorderly grabbing components, a flat belt conveyor unit, a positioning and transfer unit and an installation and transfer unit along the material flow direction, as well as a material identification unit and an industrial control unit arranged based on the auxiliary frame. Different types of junction boxes are stored in separate containers and transmitted in separate paths. Before entering the positioning and transfer unit, the material identification unit identifies the material transportation status throughout the process, and the positioning and transfer unit is responsible for the organic connection between the upstream and downstream from the pickup transmission to the installation. On the one hand, the subsequent installation and transfer unit can grab the required junction box at a specific station for installation operations, and on the other hand, it can make adjustments based on the insufficient supply of a certain station, grab in disorder and supplement the supply to the positioning and transfer unit through an independent transmission path. The present invention can reduce the failure rate of feeding and improve the production efficiency and product yield of photovoltaic modules.

Description

Technical Field

[0001] The present invention relates to a processing device in a process link of a photovoltaic component production line, and in particular to a photovoltaic component junction box installation machine and installation method suitable for disorderly grasping, belonging to the field of mechatronics application. Background Art

[0002] At present, in the assembly process of solar cell modules (referred to as photovoltaic modules), the junction box is a connector between the solar cell array and the solar charging control device in the photovoltaic module. In the past, the operator used a soldering iron and solder wire to weld the front electrode of the "front battery" to the back electrode of the "back battery", so that 36 pieces were connected in series in sequence and leads were welded on the positive and negative poles of the module string. The leads were welded to the terminal posts in the box body, the connector was connected to the solar charging control device, and the box body was glued to the back of the solar cell array, thereby realizing the assembly of the photovoltaic module.

[0003] In existing production, the positive electrode junction box, the negative electrode junction box and the intermediate junction box are all disorderly and chaotically stacked in a collection box. When the junction box is glued to the back of the solar cell array with glue, it is necessary to manually take the junction box out of the collection box and place it on the gluing workbench for gluing. This process is inconvenient for workers to operate and the consistency rate of the gluing position is low, the labor intensity of the workers is high, and the product qualification rate is low.

[0004] As can be seen from the above, the assembly process of existing photovoltaic junction boxes is complicated, the manpower and equipment costs are high, and these processes are difficult to achieve full automation, which greatly limits the improvement of photovoltaic module production efficiency. Summary of the invention

[0005] The purpose of the present invention is to provide a photovoltaic module junction box installation machine and installation method suitable for disorderly grasping, so as to improve the material conveying and installation efficiency in the junction box installation process.

[0006] The above-mentioned one object of the present invention is a photovoltaic module junction box installation machine suitable for disorderly grasping, and its technical solution is based on the expansion and customization of the photovoltaic module production line, especially based on the main frame, auxiliary frame and gantry hanger installed in one piece, and includes along the material flow direction: a storage unit, which is composed of a first turnover box, a silo and a second turnover box arranged on the auxiliary frame, and is used to classify and hold the junction box materials;

[0007] The disorderly grabbing component has a six-axis manipulator installed next to the silo, which is controlled to grab the junction box materials from each turnover box and transfer the materials to the flat belt conveyor unit at the rear;

[0008] The flat belt conveyor unit includes a pair of flipping components and a belt conveyor line corresponding to each turnover box, a flexible vibration plate connected to the bin output port is provided between the two pairs of flipping components and the belt conveyor line, and a four-axis robot with a swing arm range covering the entire flat belt conveyor unit;

[0009] The positioning and transfer unit is composed of a linear track, a guide shaft, a transfer drive, a transfer plate and a plate-mounted fixture assembled on the main frame, and is used to load three types of junction box materials in a set in different areas;

[0010] Install the transfer unit, which is hoisted on the main frame above the photovoltaic module, including a lateral movement component, a lifting component, a second clamp and a pneumatic pressing component based on the linkage assembly of the transfer hanger plate;

[0011] And the material identification unit, which consists of a first camera mounted on the gantry hanger and five fixed-point cameras distributed and mounted on the top of the auxiliary frame, wherein the first camera takes pictures of the junction box materials in the two turnover boxes at a bird's-eye view, and the fixed-point cameras collect the status of the junction box materials located at various locations of the flat belt conveyor unit at a bird's-eye view, and all cameras output to the industrial control unit through the signal bus;

[0012] And the industrial control unit is an industrial control PC built into the bottom of the sub-frame, and is interconnected with the drive control end signal lines of the six-axis manipulator, four-axis robot, flip assembly, belt conveyor line, flexible vibration plate, transfer drive and onboard fixture group.

[0013] Furthermore, the junction box material includes a positive junction box loaded into a first turnover box, an intermediate junction box loaded into a silo, and a negative junction box loaded into a second turnover box. The six-axis manipulator is controlled to continuously grab the positive junction box, continuously grab the negative junction box, or alternately grab the two junction boxes according to the loading status of the positioning and transferring unit.

[0014] Furthermore, each of the flipping components is provided with a base, a rotating shaft connected to the base, a first servo motor mounted on the outside of the base and connected to one end of the rotating shaft, and a material holding plate mounted on the top of the rotating shaft and bent at an obtuse angle; with the rotating shaft as the boundary, the material holding plate is shorter on the side close to the belt conveyor line and is connected to the belt conveyor line in the flipped state, and the material holding plate is longer on the side away from the belt conveyor line and remains horizontal in the unflipped state.

[0015] Furthermore, the silo and the flexible vibration plate are set up as a complete set of joint control, and in the operating state, the junction box material in the silo is displaced toward the flexible vibration plate; the flexible vibration plate is provided with a vibration host and a material receiving plate on its top that responds to the vibration output, and a vibration isolation tooling is provided between the bottom of the vibration host and the main frame.

[0016] Furthermore, in the material identification unit, the gantry hanger is equipped with a driven displacement slider and a camera bracket, the first camera is inverted in the camera bracket, and circulates back and forth above the first turnover box and the second turnover box, the first camera collects real-time images of the junction box materials in each turnover box, and on the basis of a three-dimensional coordinate system with a preset spatial origin, identifies the three-dimensional coordinates of at least one junction box material, and provides a reference for the six-axis manipulator to pick up materials.

[0017] Furthermore, in the material identification unit, a first fixed-point camera is suspended above the flipping assembly corresponding to the first turnover box, and images are used to identify the front and back directions of the junction box material therein; a second fixed-point camera is suspended on the belt conveyor line corresponding to the first turnover box, and images are used to re-judge whether the junction box material meets the requirements for picking up and identify the picking up coordinates for the four-axis robot; a third fixed-point camera is suspended above the flipping assembly corresponding to the second turnover box, and images are used to identify the front and back directions of the junction box material therein; a fourth fixed-point camera is suspended on the belt conveyor line corresponding to the second turnover box, and images are used to re-judge whether the junction box material meets the requirements for picking up and identify the picking up coordinates for the four-axis robot; and a fifth fixed-point camera is suspended above the flexible vibration disk, and images are used to identify the junction box material that meets the requirements for picking up and identify the picking up coordinates for the four-axis robot.

[0018] Furthermore, in the material identification unit, based on the gantry hanger and the slider and camera mount it is equipped with, the first camera is equipped with a first follow-up lighting group, and based on the sub-frame, a number of positioning lighting groups independently equipped with all fixed-point cameras are distributedly installed.

[0019] Furthermore, in the positioning and transferring unit, the transferring plate is arranged separately and provided with three workstations corresponding to the positive terminal box, the intermediate terminal box and the negative terminal box, and the onboard fixture group corresponding to each workstation includes a positioning block, a push plate and a pair of first clamps. Any kind of terminal box material is transferred into the workstation by a four-axis robot, and the push plate is driven to contact the terminal box material and abut against the positioning block. The opposite surface of the first clamp is provided with a downward-pressing guiding concave surface for preventing the terminal box material from floating in the workstation. In a clamping state in one direction coordinated by the push plate and the positioning block, the first clamp is driven to clamp the terminal box material in an orthogonal direction.

[0020] Furthermore, in the installation and transfer unit, three lateral moving components which are linearly arranged and independently driven by the displacement of the second servo motor are installed on the transfer hanger plate, and a set of hierarchically controlled lifting components, angle adaptation components, second clamps and pneumatic pressing components are integrated and installed based on the adapter bracket of each lateral moving component, wherein the lifting component is provided with a third servo motor for controlled height adjustment of the angle adaptation component, the second clamp and the pneumatic pressing component, the angle adaptation component is provided with a fourth servo motor for adjusting the installation angle of the second clamp, and the second clamp is provided with a pair of chucks for clamping the junction box material and a pair of bending grippers therebetween for guiding the bus.

[0021] Another object of the present invention is a method for installing a junction box of a photovoltaic module suitable for disorderly grabbing, which is implemented based on the above-mentioned installation machine, and includes: S1, placing corresponding types of junction box materials in a first turnover box, a silo, and a second turnover box respectively;

[0022] S2, the first camera is driven to cycle back and forth above the first turnover box and the second turnover box, and the first camera collects real-time images of the junction box materials in each turnover box and transmits them to the industrial control unit, and the industrial control unit identifies the three-dimensional coordinates of at least one junction box material based on the three-dimensional coordinate system of the preset spatial origin, and provides a reference for the six-axis manipulator to pick up materials;

[0023] S3, according to the loading state of the positioning and transfer unit and the three-dimensional coordinates obtained in S2, the six-axis manipulator is driven to continuously grab the positive terminal box, continuously grab the negative terminal box, or alternately grab the two types of terminal boxes from the turnover box, and transfer the unloading to the flat belt conveyor unit at the rear;

[0024] S4, the fixed-point camera cooperates with the industrial control PC to identify the front and back directions of the junction box material that falls into the flip assembly through S3. When the front side is facing up, the material holding plate of the flip assembly is driven to tilt, so that the junction box material slides gently onto the belt conveyor line. When the front side is facing down, the material holding plate of the flip assembly is driven to flip, so that the junction box material simulates a dumping state and then slides onto the belt conveyor line. Then, the fixed-point camera above the belt conveyor line cooperates with the industrial control PC to re-judge whether the junction box material meets the requirements for pickup and identify the pickup coordinates for the four-axis robot.

[0025] S5. Synchronously with S2 to S4, the silo and the flexible vibration plate are operated simultaneously based on the complete set of joint control. The junction box materials in the silo are displaced toward the flexible vibration plate and fall into it. Then, the flexible vibration plate is adjusted to turn over so that a part of it meets the requirements for picking up. The fixed-point camera suspended above the flexible vibration plate cooperates with the industrial control PC to identify the junction box materials that meet the requirements for picking up and identify the picking coordinates for the four-axis robot.

[0026] S6, drive the four-axis robot to poll between the two belt conveyor lines, the flexible vibration plate and the positioning and transferring unit, transfer various junction box materials to the corresponding stations of the transfer plate, and then the onboard clamp group fine-adjusts the positioning of the junction box materials and clamps them, and the fully loaded or partially empty transfer plate is driven to slide closer to the installation transfer unit;

[0027] S7. The transfer plate drives the second clamp to approach the transfer plate, grab the junction box material from the corresponding workstation, and then drive the transfer plate and the horizontal moving component to adjust the grabbed junction box material to the installation position of the photovoltaic component, and then drive the lifting component and the pneumatic pressing component to press the junction box material to the surface of each photovoltaic component and release the second clamp.

[0028] Compared with the production implementation scheme of traditional photovoltaic junction box transmission and manual installation, the installation machine and installation method of the photovoltaic module junction box of the present invention have outstanding substantive characteristics and significant progress, and the advantages are as follows:

[0029] 1. The present invention realizes fully automated operation by transmitting various junction boxes in different paths, directly connecting to the photovoltaic module production line and monitoring the status along the way, ensuring that the junction boxes corresponding to the required polarity can be input into the photovoltaic module production line to perform the installation operation.

[0030] 2. Based on the non-interference transmission of specific types of junction boxes on the left, middle and right paths, the installation machine can meet the disordered grasping settings of the six-axis manipulator, reducing the failure rate of feeding to the positioning and transfer unit.

[0031] 3. The positioning and transfer unit realizes the organic connection between the upstream and downstream of the junction box from the collection and transmission to the installation, which reflects the superior installation conditions from disorder to order, and is conducive to improving the production efficiency and yield of photovoltaic modules. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 It is a schematic diagram of the general assembly structure of the photovoltaic module junction box installation machine of the present invention.

[0033] Figure 2 yes Figure 1 The diagram shown is a schematic diagram of the assembly structure of the relevant components of the junction box installation machine at the auxiliary frame.

[0034] Figure 3 yes Figure 1 Detailed structural diagram of the random grabbing assembly and flat belt conveyor unit in the junction box installation machine shown.

[0035] Figure 4 yes Figure 1 A detailed structural diagram of the positioning and transferring unit in the junction box installation machine is shown.

[0036] Figure 5 yes Figure 1The diagram shown is a schematic diagram of the assembly structure of the relevant components of the junction box installation machine at the main frame.

[0037] Figure 6 yes Figure 5 A schematic diagram of some detailed structures of the installation and transfer unit in the junction box installation machine is shown. DETAILED DESCRIPTION

[0038] The specific implementation modes of the present invention will be further described below in conjunction with the accompanying drawings of the embodiments, so that the technical solution of the present invention is easier to understand and grasp, thereby making a clearer definition of the protection scope of the present invention.

[0039] In view of the many deficiencies exposed in the existing photovoltaic module junction box installation process, the designer of the present invention, relying on the research and development experience of production line equipment, innovatively proposed a photovoltaic module junction box installation machine and installation method suitable for disordered grabbing, in order to improve the material transfer and installation efficiency in the junction box installation process. The directional terms mentioned in the following embodiments, such as: up, down, left, right, front or back, etc., are only reference directions of the attached drawings. Therefore, the directional terms used are used to illustrate and not to limit the present invention.

[0040] like Figures 1 to 6 As shown, the photovoltaic module junction box installation machine suitable for disorderly grabbing of the present invention is customized based on the expansion of the photovoltaic module production line. In particular, the main frame 12 is integrally extended to connect the sub-frame 11 and the gantry hanger 13, and a material storage unit, disorderly grabbing components, flat belt conveyor units, positioning and transfer units, and installation and transfer units are arranged along the material flow direction based on the frame 1, and a material identification unit and an industrial control unit are also arranged at the sub-frame. The structures of each part are summarized as follows.

[0041] The material storage unit is composed of a first turnover box 22, a material bin 21, and a second turnover box 23 provided on the auxiliary frame, and is used to store the junction box materials in a classified manner; usually, the junction box materials are mainly divided into positive junction boxes 102, negative junction boxes 103, and intermediate junction boxes 101. Accordingly, the positive junction boxes are loaded into the first turnover box, the intermediate junction boxes are loaded into the material bin, and the negative junction boxes are loaded into the second turnover box. For an industrial production line, these junction box materials are randomly stacked in their respective containers.

[0042] The disordered grabbing component is mainly a six-axis manipulator 3 positioned and installed next to the silo 21. The end of the six-axis manipulator is provided with a first clamp (not shown) with an adjustable angle. It is controlled by the industrial control PC to grab the junction box materials from each turnover box and transfer the materials to the flat belt conveyor unit at the rear. Here, the six-axis manipulator mainly reflects the disorder of the grabbing action. It is not necessary to poll the storage unit in sequence, but is controlled to continuously grab the positive terminal box, continuously grab the negative terminal box, or alternately grab the two types of terminal boxes according to the loading status of the positioning and transfer unit.

[0043] The flat belt conveyor unit includes a left-way flip assembly 421 and a left-way belt conveyor line 422 corresponding to the first turnover box 22, a right-way flip assembly 431 and a right-way belt conveyor line 432 corresponding to the second turnover box 23, and a flexible vibration plate 41 connected to the output port of the material bin 21 is provided between the two pairs of flip assemblies and the belt conveyor line, and a four-axis robot 5 whose swing arm range covers the entire flat belt conveyor unit. The four-axis robot clamps the required junction box from the left-way belt conveyor line 422, the right-way belt conveyor line 432 and the material tray 411 of the flexible vibration plate through the second clamp 51 with an opening downward at the end. The flip assembly is mainly used to perform the flip operation on the positive or negative junction box placed therein as required, because the materials are randomly stacked in the turnover box, and the six-axis manipulator cannot ensure that the junction box material clock faces up, which will cause trouble to the subsequent transfer and installation operations, so the junction box material that falls on the belt conveyor line needs to face up.

[0044] The positioning and transfer unit 6 is composed of a linear rail 62, a guide shaft 61, a transfer driver, a transfer plate and an onboard clamp assembly mounted on the main frame 12, and is used to load three types of junction box materials in a set in different areas. In addition, due to the mobility of the transfer plate, in order to prevent the junction box materials loaded at various locations from being displaced and shaken or falling due to inertia, it is also necessary to use the onboard clamp assembly to controllably clamp each junction box material to strengthen positioning.

[0045] The transfer unit 7 is installed and hoisted on the main frame above the photovoltaic module 8, including a lateral moving component 72, a lifting component, a second clamp and a pneumatic pressing component based on the linkage of the transfer hanging plate 71. When the transfer plate transports the material into place, the position of the second clamp is adjusted and the material is taken downward, and then transferred to the position on the surface of the photovoltaic module where it needs to be installed.

[0046] The material identification unit is composed of a first camera 24 mounted on the gantry hanger 13 and five fixed-point cameras distributedly mounted on the top of the sub-frame 11. The first camera 24 photographs the junction box materials in the two turnover boxes at a bird's-eye view, and the fixed-point cameras collect the status of the junction box materials located at various locations of the flat belt conveyor unit at a bird's-eye view. All cameras output to the industrial control unit through the signal bus.

[0047] The industrial control unit is an industrial control PC built into the bottom of the sub-frame 11, and is interconnected with the six-axis manipulator 3, the four-axis robot 5, the flip assembly, the belt conveyor line, the flexible vibration plate 41, the transfer driver and the onboard fixture group. In addition, the industrial control PC has built-in image recognition software to analyze the position coordinates and part orientation status of the target object (junction box material) in real time based on the photo signal input from the material recognition unit.

[0048] From the detailed structural composition of each part to realize the preset functions, such as Figure 3 As shown, each of the above-mentioned flipping components is provided with a base, a rotating shaft connected to the base, a first servo motor attached to the outside of the base and connected to one end of the rotating shaft, and a material holding plate attached to the top of the rotating shaft and bent at an obtuse angle. With the rotating shaft as the boundary, the material holding plate is shorter on the side close to the belt conveyor line, and is connected to the belt conveyor line in the flipped state. The material holding plate is longer on the side away from the belt conveyor line, and remains horizontal in the unflipped state. When the six-axis manipulator grabs the junction box material and puts it in the flipping component, it mainly refers to placing it on the main body of the material holding plate that remains horizontal and occupies a larger format, so that the fixed-point camera suspended on the top can take pictures. The remaining part of the material holding plate that occupies a smaller format mainly plays a transitional role to prevent the junction box material from accidentally falling during the flow from the flipping component to the belt conveyor line. In addition, by adjusting the rotation amplitude output by the first servo motor, the material holding plate can be tilted at a small angle or flipped at a larger angle, so that the orientation of the junction box material on it can be controlled.

[0049] The above-mentioned silo 21 and flexible vibration plate 41 are a complete set of joint control settings, and the junction box material (i.e., the intermediate junction box) in the silo is displaced toward the flexible vibration plate in the operating state, and the finished product components related to Dannickel can be selected. The flexible vibration plate is provided with a vibration host and a material tray 411 on its top that responds to the vibration output, and the intermediate junction boxes fall into it one by one and are laid out discretely, and a vibration isolation tooling is provided between the bottom of the vibration host and the main frame, so that the frame of the installation machine remains stationary, and the vibration output is only concentrated in the material tray. When the fixed-point camera identifies that a certain intermediate junction box is in a reverse-facing state, the four-axis robot picks up the material to either side of the flip assembly to turn the part over on the basis of the positioning coordinates, and then picks up the material for the second time and transports it to the positioning transfer unit; when the fixed-point camera identifies that a certain intermediate junction box is in a front-facing state, the material can be directly picked up and transported.

[0050] In the above-mentioned material identification unit, the gantry hanger 13 is equipped with a driven displacement slider (composed of a conventional linear drive mechanism, the driver identification is omitted) and a camera hanger integrated with the slider, and the first camera 24 is inverted in the camera hanger and circulates back and forth over the first turnover box and the second turnover box. The first camera collects real-time images of the junction box materials in each turnover box, and identifies the three-dimensional coordinates of at least one junction box material on the basis of a three-dimensional coordinate system with a preset spatial origin (for example, the origin is a point on the side of the six-axis manipulator close to the silo or the center point of the above-mentioned material tray, etc.) and the cooperation of the industrial control PC, and provides a reference for the six-axis manipulator to pick up materials.

[0051] Similarly, in the material identification unit, the first fixed-point camera is suspended above the flip assembly corresponding to the first turnover box, and the image identifies the front and back directions of the junction box material. The second fixed-point camera is suspended on the belt conveyor corresponding to the first turnover box, and the image re-judges whether the junction box material meets the pickup requirements and identifies the pickup coordinates for the four-axis robot. The third fixed-point camera is suspended above the flip assembly corresponding to the second turnover box, and the image identifies the front and back directions of the junction box material. The fourth fixed-point camera is suspended on the belt conveyor corresponding to the second turnover box, and the image re-judges whether the junction box material meets the pickup requirements and identifies the pickup coordinates for the four-axis robot. The four fixed-point cameras 44 are positioned and attached above each shooting point in a rectangular distribution. The remaining single fifth fixed-point camera 45 is suspended above the flexible vibration plate, and the image identifies the junction box material that meets the pickup requirements and identifies the pickup coordinates for the four-axis robot.

[0052] Since the frame of the entire installation machine is closed by installing various types of plates, in order to avoid insufficient light affecting the framing and image quality of each camera, in the material identification unit, based on the gantry hanger and its mounted slider and camera hanger, the first camera is equipped with a follow-up first lighting group, and based on the sub-frame, a number of positioning lighting groups independently equipped with all fixed-point cameras are distributedly installed, such as Figure 2 shown.

[0053] In addition, Figure 4 As shown, the transfer plate in the positioning and transfer unit is arranged separately and provided with three stations 63b, 63a, and 63c corresponding to the positive terminal box, the intermediate terminal box, and the negative terminal box, and the onboard fixture group corresponding to each station is the same. Taking a station 63b corresponding to the positive terminal box as an example, it includes a positioning block (not marked), a push plate 64, and a pair of first clamps 631. After the positive terminal box is transferred to the station by the four-axis robot, the push plate 64 is used to be driven to contact the outer shell of the terminal box material and abut against the positioning block. Since the positive terminal box also integrates a cable tied into several turns, it is difficult for the shell of the terminal box to be fully contacted and placed flat on the station without external force. Therefore, the opposite surface of the first clamping jaw 631 is provided with a downward pressure guiding concave surface to prevent the positive terminal box from floating in the workstation, and in a clamping state in one direction matched by the push plate and the positioning block, the first clamping jaw is driven to clamp the terminal box material in an orthogonal direction and press the terminal box material against the workstation. The implementation of the other two workstations is the same.

[0054] Finally Figure 5 and Figure 6As shown, the transfer hanging plate 71 in the installation and transfer unit is actually installed in a pair of hanging cabinets and their driving mechanisms preset on the top of the main frame, and is controlled to move and adjust the position along the length direction of the photovoltaic module. The transfer hanging plate 71 is equipped with three linearly arranged horizontal moving components 72 that are independently driven by the second servo motor, and a set of hierarchical joint control lifting components, angle adaptation components, second clamps and pneumatic pressing components are integrated and installed based on the adapter bracket of each horizontal moving component, wherein the lifting component is provided with a third servo motor (the perspective in the figure is biased inward and not marked) for controlled driving of the angle adaptation component, the second clamp and the pneumatic pressing component for height adjustment, and the angle adaptation component is provided with a fourth servo motor 73 for adjusting the installation angle of the second clamp. Take a horizontal moving component located in the middle as an example, wherein the second clamp 741 is provided with a pair of clamps 7411 for clamping the junction box material and a pair of bending grips 7412 for guiding the busbar. In this unit, the mechanisms for picking up and installing materials corresponding to various junction box materials are all configured in the same manner and independently controlled, that is, each servo motor, each pneumatic valve controller, positioning sensor, remote module 751, post-installation inspection module, etc. are all operated in accordance with each junction box material and its installation position. Regarding the more specific installation implementation of this part, detailed development is omitted on the premise that the existing public document (application number: 2022113898987) has already disclosed it in detail.

[0055] The specific operation process of the photovoltaic module junction box installation method after the installation machine is put into use includes the following steps: S1, corresponding types of junction box materials are placed in the first turnover box, the silo, and the second turnover box respectively. This part is conventional loading, and the side panels at the corresponding positions have feeding ports for the two turnover boxes and the silo. When the first camera identifies or determines that a specific station of the transfer board is unloaded for a long time, the industrial control PC and its peripherals can be used to warn and replenish materials.

[0056] S2, the first camera is driven to cycle back and forth over the first turnover box and the second turnover box, and the first camera collects real-time images of the junction box materials in each turnover box and transmits them to the industrial control unit, and the industrial control unit identifies the three-dimensional coordinates of at least one junction box material based on the three-dimensional coordinate system of the preset spatial origin, and provides a reference for the six-axis manipulator to pick up materials. Here, the real-time image often contains several junction box materials and their recognizable three-dimensional coordinates, so the industrial control PC usually gives the six-axis manipulator a three-dimensional coordinate of a junction box material that is closest or most suitable for it to grab.

[0057] S3, according to the loading status of the positioning and transfer unit and the three-dimensional coordinates obtained by S2, the six-axis manipulator is driven to continuously grab the positive terminal box, continuously grab the negative terminal box, or alternately grab the two types of terminal boxes from the turnover box, and transfer the discharge to the flat belt conveyor unit at the rear. Due to the objective existence of abnormalities in the transmission of terminal box materials and the variability of installation operations, the demand for various terminal box materials is not consistent, so the six-axis manipulator's material collection has a disordered characteristic, and part of the three-dimensional coordinates obtained by S2 will be abandoned or reserved.

[0058] S4. The fixed-point camera cooperates with the industrial control PC to identify the front and back directions of the junction box material that falls into the flip component through S3. When the front side is facing up, the material holding plate of the flip component is driven to tilt (10°~20°) to make the junction box material slide smoothly onto the belt conveyor line. When the front side is facing down, the material holding plate of the flip component is driven to flip (90°~100°) to simulate the tipping state of the junction box material and then slide onto the belt conveyor line. Then, the fixed-point camera above the belt conveyor line cooperates with the industrial control PC to re-judge whether the junction box material meets the requirements for pickup and identify the pickup coordinates for the four-axis robot.

[0059] S5. Synchronously with S2 to S4, the silo and the flexible vibration plate are operated simultaneously based on the complete set of joint control. The junction box materials in the silo are displaced toward the flexible vibration plate and fall into it. Then, the flexible vibration plate is adjusted to flip so that part of it meets the requirements for picking up. The fixed-point camera suspended above the flexible vibration plate cooperates with the industrial control PC to image-recognize the junction box materials that meet the requirements for picking up and identify the coordinates for picking up by the four-axis robot. When there is no intermediate junction box that meets the requirements for picking up, as described above, one of the materials can be picked up and adjusted to meet the requirements for picking up with the help of the idle flip assembly.

[0060] S6, drive the four-axis robot to poll between the two belt conveyor lines, the flexible vibration plate and the positioning and transferring unit, transfer various junction box materials to the corresponding stations of the transfer plate, and then the onboard clamp group fine-tunes the positioning and clamps the junction box materials. The fully loaded or partially empty transfer plate is driven to slide closer to the installation transfer unit.

[0061] S7. The transfer hanger drives the second clamp to approach the transfer plate, grabs the junction box material from the corresponding workstation (the first clamp is released at this time), and then drives the transfer hanger and the horizontal moving component to adjust the grabbed junction box material to the installation position of the photovoltaic module, and then drives the lifting component and the pneumatic pressing component to press the junction box material to the surface of each photovoltaic module, and then releases the second clamp.

[0062] From the above detailed description of the photovoltaic module junction box installation machine and installation method suitable for disordered grabbing and the embodiments of the present invention, it can be seen that, compared with the production implementation scheme of traditional photovoltaic junction box transmission and manual installation, it has outstanding substantial characteristics and significant advancement, and its advantages include the following aspects.

[0063] 1. The present invention realizes fully automated operation by transmitting various junction boxes in different paths, directly connecting to the photovoltaic module production line and monitoring the status along the way, ensuring that the junction boxes corresponding to the required polarity can be input into the photovoltaic module production line to perform the installation operation.

[0064] 2. Based on the non-interference transmission of specific types of junction boxes on the left, middle and right paths, the installation machine can meet the disordered grasping settings of the six-axis manipulator, reducing the failure rate of feeding to the positioning and transfer unit.

[0065] 3. The positioning and transfer unit realizes the organic connection between the upstream and downstream of the junction box from the collection and transmission to the installation, which reflects the superior installation conditions from disorder to order, and is conducive to improving the production efficiency and yield of photovoltaic modules.

[0066] In addition to the above embodiments, the present invention may also have other implementation modes. Any technical solutions formed by equivalent replacement or equivalent transformation shall fall within the scope of protection required by the present invention.

Claims

1. Photovoltaic module junction box installation machine suitable for disorderly grasping, based on the expansion and customization of photovoltaic module production line, characterized by: Based on the integrated main frame, auxiliary frame and gantry hanger, the material flow direction includes: The material storage unit is composed of a first turnover box, a material bin, and a second turnover box provided on the auxiliary frame, and is used to classify and store materials of the junction boxes; The disorderly grabbing component has a six-axis manipulator installed next to the silo, which is controlled to grab the junction box materials from each turnover box and transfer the materials to the flat belt conveyor unit at the rear; The flat belt conveyor unit includes a pair of flipping components and a belt conveyor line corresponding to each turnover box, a flexible vibration plate connected to the bin output port is provided between the two pairs of flipping components and the belt conveyor line, and a four-axis robot with a swing arm range covering the entire flat belt conveyor unit; The positioning and transfer unit is composed of a linear track, a guide shaft, a transfer drive, a transfer plate and a plate-mounted fixture assembled on the main frame, and is used to load three types of junction box materials in a set in different areas; Install the transfer unit, which is hoisted on the main frame above the photovoltaic module, including a lateral movement component, a lifting component, a second clamp and a pneumatic pressing component based on the linkage assembly of the transfer hanger plate; And the material identification unit, which consists of a first camera mounted on the gantry hanger and five fixed-point cameras distributed and mounted on the top of the auxiliary frame, wherein the first camera takes pictures of the junction box materials in the two turnover boxes at a bird's-eye view, and the fixed-point cameras collect the status of the junction box materials located at various locations of the flat belt conveyor unit at a bird's-eye view, and all cameras output to the industrial control unit through the signal bus; The industrial control unit is an industrial control PC built into the bottom of the sub-frame, and is interconnected with the drive control end signal lines of the six-axis manipulator, four-axis robot, flip assembly, belt conveyor line, flexible vibration plate, transfer drive and onboard fixture group.

2. The photovoltaic module junction box installation machine suitable for disorderly grabbing according to claim 1, characterized in that: The junction box material includes a positive junction box loaded into a first turnover box, an intermediate junction box loaded into a silo, and a negative junction box loaded into a second turnover box. The six-axis manipulator is controlled to continuously grab the positive junction box, continuously grab the negative junction box, or alternately grab the two types of junction boxes according to the loading status of the positioning and transferring unit.

3. The photovoltaic module junction box installation machine suitable for disorderly grabbing according to claim 1, characterized in that: Each of the flipping components is provided with a base, a rotating shaft connected to the base, a first servo motor installed on the outside of the base and connected to one end of the rotating shaft, and a material holding plate installed on the top of the rotating shaft and bent at an obtuse angle; with the rotating shaft as the boundary, the material holding plate is shorter on the side close to the belt conveyor line and is connected to the belt conveyor line in the flipped state, and the material holding plate is longer on the side away from the belt conveyor line and remains horizontal in the unflipped state.

4. The photovoltaic module junction box installation machine suitable for disorderly grabbing according to claim 1, characterized in that: The silo and the flexible vibration plate are set up as a complete set of joint control, and the junction box material in the silo is displaced toward the flexible vibration plate in the operating state; the flexible vibration plate is provided with a vibration host and a material receiving plate on its top that responds to the vibration output, and a vibration isolation tooling is provided between the bottom of the vibration host and the main frame.

5. The photovoltaic module junction box installation machine suitable for disorderly grabbing according to claim 1, characterized in that: In the material identification unit, the gantry hanger is equipped with a driven displacement slider and a camera bracket. The first camera is inverted in the camera bracket and circulates back and forth above the first turnover box and the second turnover box. The first camera collects real-time images of the junction box materials in each turnover box, and identifies the three-dimensional coordinates of at least one junction box material based on a three-dimensional coordinate system with a preset spatial origin, providing a reference for the six-axis manipulator to pick up materials.

6. The photovoltaic module junction box installation machine suitable for disorderly grabbing according to claim 1, characterized in that: In the material identification unit, the first fixed-point camera is suspended above the flipping assembly corresponding to the first turnover box, and images are used to identify the front and back directions of the junction box material. The second fixed-point camera is suspended on the belt conveyor line corresponding to the first turnover box, and images are used to re-judge whether the junction box material meets the requirements for picking up and identify the picking coordinates for the four-axis robot. The third fixed-point camera is suspended above the flipping assembly corresponding to the second turnover box, and images are used to identify the front and back directions of the junction box material. The fourth fixed-point camera is suspended on the belt conveyor line corresponding to the second turnover box, and images are used to re-judge whether the junction box material meets the requirements for picking up and identify the picking coordinates for the four-axis robot. The fifth fixed-point camera is suspended above the flexible vibration disk, and images are used to identify the junction box material that meets the requirements for picking up and identify the picking coordinates for the four-axis robot.

7. The photovoltaic module junction box installation machine suitable for disorderly grabbing according to claim 1, characterized in that: In the material identification unit, based on the gantry hanger and the slider and camera bracket it is equipped with, the first camera is equipped with a follow-up first lighting group, and based on the sub-frame, a number of positioning lighting groups independently equipped with all fixed-point cameras are distributedly installed.

8. The photovoltaic module junction box installation machine suitable for disorderly grabbing according to claim 1, characterized in that: In the positioning and transferring unit, the transferring plate is arranged separately and provided with three workstations corresponding to the positive terminal box, the intermediate terminal box and the negative terminal box, and the onboard fixture group corresponding to each workstation includes a positioning block, a push plate and a pair of first clamps. Any kind of terminal box material is transferred into the workstation by a four-axis robot, and the push plate is driven to contact the terminal box material and abut against the positioning block. The opposite surface of the first clamp is provided with a downward-pressing guiding concave surface for preventing the terminal box material from floating in the workstation. In a clamping state in one direction coordinated by the push plate and the positioning block, the first clamp is driven to clamp the terminal box material in an orthogonal direction.

9. The photovoltaic module junction box installation machine suitable for disorderly grabbing according to claim 1, characterized in that: In the installation and transfer unit, three linearly arranged lateral moving components independently driven by the displacement of the second servo motor are installed on the transfer hanger plate, and a set of hierarchically controlled lifting components, angle adaptation components, second clamps and pneumatic pressing components are integrated and installed based on the adapter bracket of each lateral moving component, wherein the lifting component is provided with a third servo motor for controlled height adjustment of the angle adaptation component, the second clamp and the pneumatic pressing component, the angle adaptation component is provided with a fourth servo motor for adjusting the installation angle of the second clamp, and the second clamp is provided with a pair of chucks for clamping the junction box material and a pair of bending grippers therebetween for guiding the bus.

10. A photovoltaic module junction box installation method suitable for disorderly grabbing, implemented based on the installation machine of claim 1, characterized in that include: S1. Place corresponding types of junction box materials in the first turnover box, the material bin, and the second turnover box respectively; S2, the first camera is driven to cycle back and forth above the first turnover box and the second turnover box, and the first camera collects real-time images of the junction box materials in each turnover box and transmits them to the industrial control unit, and the industrial control unit identifies the three-dimensional coordinates of at least one junction box material based on the three-dimensional coordinate system of the preset spatial origin, and provides a reference for the six-axis manipulator to pick up materials; S3, according to the loading state of the positioning and transfer unit and the three-dimensional coordinates obtained in S2, the six-axis manipulator is driven to continuously grab the positive terminal box from the first turnover box, continuously grab the negative terminal box from the second turnover box, or alternately grab the two types of terminal boxes from the two turnover boxes, and transfer the unloading to the flat belt conveyor unit at the rear; S4, the fixed-point camera cooperates with the industrial control PC to identify the front and back directions of the junction box material that falls into the flip assembly through S3. When the front side is facing up, the material holding plate of the flip assembly is driven to tilt, so that the junction box material slides gently onto the belt conveyor line. When the front side is facing down, the material holding plate of the flip assembly is driven to flip, so that the junction box material simulates a dumping state and then slides onto the belt conveyor line. Then, the fixed-point camera above the belt conveyor line cooperates with the industrial control PC to re-judge whether the junction box material meets the requirements for pickup and identify the pickup coordinates for the four-axis robot. S5. Synchronously with S2 to S4, the silo and the flexible vibration plate are operated simultaneously based on the complete set of joint control. The junction box materials in the silo are displaced toward the flexible vibration plate and fall into it. Then, the flexible vibration plate is adjusted to turn over so that a part of it meets the requirements for picking up. The fixed-point camera suspended above the flexible vibration plate cooperates with the industrial control PC to identify the junction box materials that meet the requirements for picking up and identify the picking coordinates for the four-axis robot. S6, drive the four-axis robot to poll between the two belt conveyor lines, the flexible vibration plate and the positioning and transferring unit, transfer various junction box materials to the corresponding stations of the transfer plate, and then the onboard clamp group fine-adjusts the positioning of the junction box materials and clamps them, and the fully loaded or partially empty transfer plate is driven to slide closer to the installation transfer unit; S7. The transfer plate drives the second clamp to approach the transfer plate, grab the junction box material from the corresponding workstation, and then drive the transfer plate and the horizontal moving component to adjust the grabbed junction box material to the installation position of the photovoltaic component, and then drive the lifting component and the pneumatic pressing component to press the junction box material to the surface of each photovoltaic component and release the second clamp.

Images