Photovoltaic module layering device and control method thereof

Abstract

The present application relates to a photovoltaic module layering device and a control method thereof, and belongs to the field of photovoltaic modules. The photovoltaic module comprises a glass plate, a first EVA adhesive layer, a silicon plate, a second EVA adhesive layer and a back plate in sequence. By irradiating and heating the photovoltaic module, the first EVA adhesive layer and the second EVA adhesive layer in the photovoltaic module can be melted and softened to a certain extent, making it easier to separate the first EVA adhesive layer and the second EVA adhesive layer from the glass plate or the silicon plate during cutting and separation, thereby reducing the wear of the tool on the glass plate and the silicon plate. The tool can be accurately aligned through the visual component, and the vibration frequency and vibration amplitude of the ultrasonic vibration knife can be adjusted in real time according to the real-time elastic modulus of the first EVA adhesive layer or the second EVA adhesive layer to avoid excessive force of the ultrasonic vibration knife, thereby maintaining accurate cutting accuracy during cutting and greatly improving the integrity of the silicon plate and glass plate during recycling.

Description

Technical Field

[0001] The present application relates to the field of photovoltaic modules, and in particular to a photovoltaic module layering device and a control method thereof. Background Art

[0002] As a large number of previously installed crystalline silicon photovoltaic modules gradually enter retirement, the efficient and environmentally friendly disposal of these discarded panels, preventing them from becoming a new source of environmental pollution, has become a critical issue that needs to be addressed. PV module disassembly is a crucial step in PV module recycling. If suitable recycling processes can be used to recover intact silicon wafers from discarded modules, the manufacturing cost of PV modules can be significantly reduced.

[0003] Photovoltaic modules are composed of a laminated glass sheet, EVA adhesive layer, silicon sheet, EVA adhesive layer, and backsheet. Separating the EVA adhesive layer is the most challenging part of module recycling, and is typically accomplished through mechanical disassembly, thermal decomposition, and chemical methods. Chemical methods, such as dissolution with inorganic acids or organic solvents, offer the advantage of obtaining intact glass and silicon wafers, but they consume large amounts of acid, are slow, and require secondary wastewater treatment. Thermal decomposition is more efficient and can also yield intact glass, but it consumes significant energy and produces significant gaseous pollutants. Traditional mechanical disassembly methods, while free of these environmental issues, do not pose these environmental risks. However, due to the high adhesion between the structural layers of photovoltaic modules, traditional mechanical disassembly methods involve manually pulling the glass and silicon wafer layers apart with pliers. The uncontrollable force of the mechanical disassembly can cause the silicon wafer and glass layers to break or remain, resulting in poor recycling quality. Furthermore, the slow disassembly process is not suitable for large-scale recycling operations.

[0004] Currently, no effective solution has been proposed to the problem that existing mechanical disassembly methods are prone to damaging the silicon plate and glass during disassembly, making it difficult to separate the complete silicon wafer and glass. Summary of the Invention

[0005] The present invention provides a photovoltaic module layering device and a control method thereof to solve the problem that the existing mechanical disassembly method is prone to damage the silicon plate and glass during disassembly.

[0006] In the first aspect, the present invention provides a photovoltaic module layering device, wherein the photovoltaic module comprises a glass plate, a first EVA adhesive layer, a silicon plate, a second EVA adhesive layer and a back plate in sequence, the first side of the silicon plate is bonded by the first EVA adhesive layer, and the second side of the silicon plate is bonded to the back plate by the second EVA adhesive layer, and the layering device comprises: a machine tool, a conveying unit, a preheating assembly, a cutting unit and a separation auxiliary assembly. A gantry is provided on the top of the machine tool, and the two ends of the gantry are fixedly connected to the two sides of the top of the machine tool respectively. The conveying unit comprises a linear module and a first vacuum suction cup, the linear module is mounted on the top of the machine tool, the first vacuum suction cup is mounted on the moving end of the linear module, and the first vacuum suction cup is used to adsorb the back plate of the photovoltaic module. The preheating assembly is mounted on the inner top of the gantry and is used to irradiate and heat the photovoltaic module below the gantry. The cutting unit includes an ultrasonic vibrating blade and a set of symmetrical blade holders. The two blade holders are mounted on the inner sides of the two ends of the gantry, and the ultrasonic vibrating blade is mounted between the two blade holders. The ultrasonic vibrating blade is used to cut the first EVA adhesive layer of the heated photovoltaic module to separate the glass and silicon panels of the photovoltaic module, or to cut the second EVA adhesive layer of the heated photovoltaic module to separate the back panel and silicon panel of the photovoltaic module. The separation auxiliary component includes a robotic arm and a second vacuum suction cup. The mechanical interface of the robotic arm is connected to the second vacuum suction cup. The second vacuum suction cup is used to absorb the glass panel of the photovoltaic module to separate the glass and silicon panels after the first EVA adhesive layer is cut, or to absorb the silicon panel of the photovoltaic module to separate the back panel and silicon panel after the second EVA adhesive layer is cut.

[0007] Furthermore, the photovoltaic module layering device further comprises:

[0008] The force sensor is mounted on the second vacuum chuck and is used to detect the stress of the second vacuum chuck.

[0009] A processor configured to:

[0010] Acquire real-time stress data of the second vacuum suction cup through a force sensor, and determine real-time stress data of the first EVA adhesive layer or the second EVA adhesive layer based on the real-time stress data of the second vacuum suction cup;

[0011] Determine the real-time elastic modulus of the first EVA adhesive layer according to the real-time stress data of the first EVA adhesive layer; or determine the real-time elastic modulus of the second EVA adhesive layer according to the real-time stress data of the second EVA adhesive layer;

[0012] The vibration frequency and vibration amplitude of the ultrasonic vibration knife are adjusted in real time according to the real-time elastic modulus of the first EVA adhesive layer or the second EVA adhesive layer.

[0013] Furthermore, the photovoltaic module stratification device also includes a processor, a guide rail is symmetrically installed on the inner side of the gantry, a tool fixing frame is slidably installed on the guide rail, a movable structure for lifting the tool fixing frame is provided on the guide rail, a rotatable locking head is provided on the tool fixing frame, a driving structure for rotating the locking head is provided in the tool fixing frame, an ultrasonic vibration knife is installed on the locking head, and a visual component is installed on the tool fixing frame.

[0014] The processor is configured to:

[0015] Acquire real-time image data of the ultrasonic vibration knife through a visual component, compare the real-time image data with target image data, determine a real-time tool state of the ultrasonic vibration knife, and determine a real-time angle of the locking head and / or a real-time height of the tool fixing frame according to the real-time tool state of the ultrasonic vibration knife;

[0016] Maintain the real-time angle of the locking head at a target angle and / or control the real-time height of the tool holder at a target height.

[0017] Furthermore, the driving structure includes a motor, which is installed inside the tool fixing frame, and the motor driving end drives the locking head to rotate.

[0018] Furthermore, the visual component includes a camera and an LED light, both of which are mounted on a tool holder for photographing the ultrasonic vibration knife and the photovoltaic module.

[0019] Furthermore, the first vacuum suction cup includes a suction cup shell and a plurality of square suction cup openings, and the square suction cup openings are made of high-temperature resistant material.

[0020] Furthermore, the preheating component includes an infrared lamp tube, a lampshade and a temperature sensor. The lampshade is installed on the inner top of the gantry, the infrared lamp tube is installed on the inner top of the lampshade, and the temperature sensor is installed on the inner top of the lampshade to monitor the temperature of the photovoltaic component.

[0021] The photovoltaic module layering device further includes a processor configured to:

[0022] The real-time temperature of the photovoltaic module is obtained through the temperature sensor, and the heating frequency of the infrared lamp is controlled to keep the real-time temperature within the target temperature range.

[0023] Furthermore, the infrared lamp is a black tube heating lamp.

[0024] Furthermore, the linear module includes a ball screw guide, a drive motor and a fixed plate. The ball screw guide and the drive motor are installed on the top of the machine tool. The drive motor is installed and connected to the driving end of the ball screw guide. The fixed plate is installed at the moving end of the ball screw guide, and the fixed plate is fixed to the bottom of the first vacuum suction cup.

[0025] In a second aspect, the present invention provides a control method for a photovoltaic module layering device, the control method comprising: step S101, step S102, step S103, step S104, step S105, step S106, step S107, step S108 and step S109.

[0026] Step S101, controlling the first vacuum suction cup to adsorb the photovoltaic module, and controlling the linear module to drive the photovoltaic module to move to the cutting starting position of the ultrasonic vibration knife;

[0027] Step S102: Control the black tube heating lamp to heat the photovoltaic module. During the heating process, the real-time temperature of the photovoltaic module is obtained through the temperature sensor, and the heating frequency of the infrared lamp is controlled to keep the real-time temperature within the target temperature range.

[0028] Step S103, controlling the LED light to illuminate the contact area between the ultrasonic vibration knife and the photovoltaic module;

[0029] Step S104: acquiring real-time image data of the ultrasonic vibrating blade through a camera, comparing the real-time image data with the target image data, determining the real-time angle between the ultrasonic vibrating blade and the locking head, and controlling the driving structure so that the real-time angle between the ultrasonic vibrating blade and the locking head is the target angle;

[0030] Step S105, controlling the linear module to drive the photovoltaic module to move to the cutting end position of the ultrasonic vibration knife;

[0031] Step S106: During the cutting process, real-time image data of the ultrasonic vibration knife is acquired through a camera, the real-time image data is compared with the target image data, and the real-time tool state of the ultrasonic vibration knife is determined. The real-time angle of the locking head and / or the real-time height of the tool holder are determined based on the real-time tool state of the ultrasonic vibration knife, and the driving structure is controlled so that the real-time angle of the locking head is the target angle and / or the moving structure is controlled so that the real-time height of the tool holder is the target height;

[0032] Step S107: Control the robotic arm to move the second vacuum suction cup to absorb the glass plate or the silicon plate, obtain real-time stress data of the second vacuum suction cup through the force sensor, and determine the real-time stress data of the first EVA adhesive layer or the second EVA adhesive layer based on the real-time stress data of the second vacuum suction cup;

[0033] Step S108, determining the real-time elastic modulus of the first EVA adhesive layer according to the real-time stress data of the first EVA adhesive layer; or determining the real-time elastic modulus of the second EVA adhesive layer according to the real-time stress data of the second EVA adhesive layer;

[0034] Step S109: adjusting the vibration frequency and amplitude of the ultrasonic vibration knife in real time according to the real-time elastic modulus of the first EVA adhesive layer or the second EVA adhesive layer until the separation of the EVA adhesive layer is completed.

[0035] Compared with the related art, this application has the following beneficial effects:

[0036] 1. By irradiating and heating the photovoltaic module, the first EVA adhesive layer and the second EVA adhesive layer in the photovoltaic module can be melted and softened to a certain extent. This makes it easier to separate the first EVA adhesive layer and the second EVA adhesive layer from the glass plate or silicon plate during cutting and separation, thereby reducing the wear of the tool on the glass plate and the silicon plate. The visual component can accurately align the tool and adjust the vibration frequency and vibration amplitude of the ultrasonic vibration knife in real time according to the real-time elastic modulus of the first EVA adhesive layer or the second EVA adhesive layer to avoid excessive force of the ultrasonic vibration knife, thereby maintaining precise cutting accuracy during cutting and greatly improving the integrity of the silicon plate and glass plate during recycling.

[0037] 2. The characteristic of black tube heating lamps is that they can generate heat but not emit light. The purpose of using black tube heating lamps is to prevent the silicon plate from being directly exposed to light, thereby causing light pollution to the silicon plate, which is beneficial to improving the quality of silicon plate recycling.

[0038] 3. The first vacuum suction cup is composed of multiple suction cup units. Each suction cup unit adopts a "U"-shaped groove and small square design, which makes the photovoltaic module and the suction cup fit perfectly and the sealing effect is better, ensuring the stability of the photovoltaic module during the cutting process. The sealing ring material can withstand high temperatures of 200°C, so that the transmission unit can work normally under preheating conditions.

[0039] 4. By adjusting the power and exposure time of the infrared lamp, the temperature of the EVA layer can be precisely controlled to ensure it reaches the optimal softening state. This precise temperature control helps improve the recovery rate and integrity of materials after photovoltaic module disassembly.

[0040] 5. The advantage of a vacuum cup is that it provides uniform and stable suction, which is particularly important for smooth, fragile materials such as photovoltaic panels. By precisely controlling the vacuum level, the panels can be protected from damage due to external forces during transport.

[0041] The details of one or more embodiments of the present application are set forth in the following drawings and description to make other features, objects, and advantages of the present application more readily apparent. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 It is a device diagram of the present invention.

[0043] Figure 2 yes Figure 1Schematic diagram of the transmission unit structure.

[0044] Figure 3 This is a schematic diagram of the installation structure of the guide rail, tool holder, locking head and vision component.

[0045] Figure 4 It is a schematic diagram of the preheating component structure.

[0046] Figure 5 This is a schematic diagram of the layered working of photovoltaic modules.

[0047] Figure 6 It is a hierarchical flow chart of the device. DETAILED DESCRIPTION

[0048] In order to more clearly understand the purpose, technical solutions and advantages of the present application, the present application is described and illustrated below in conjunction with the accompanying drawings and embodiments.

[0049] Unless otherwise defined, the technical terms or scientific terms involved in this application should have the general meaning understood by people with ordinary skills in the technical field to which this application belongs. "One", "an", "a kind of", "the", "these" and similar words in this application do not represent quantitative restrictions, and they can be singular or plural. The terms "include", "comprise", "have" and any variants involved in this application are intended to cover non-exclusive inclusion. For example, a process, method and system, product or equipment comprising a series of steps or modules (units) is not limited to the listed steps or modules (units), but may include unlisted steps or modules (units), or may include other steps or modules (units) inherent to these processes, methods, products or equipment. "Connect", "be connected", "couple" and similar words involved in this application are not limited to physical or mechanical connections, but may include electrical connections, whether directly or indirectly. "Multiple" involved in this application refers to two or more. "And / or" describes the relationship between related objects, indicating that three possible relationships exist. For example, "A and / or B" can represent: A exists alone, A and B exist simultaneously, and B exists alone. Generally, the character " / " indicates that the related objects are in an "or" relationship. The terms "first," "second," "third," etc. used in this application are only used to distinguish similar objects and do not represent a specific ordering of the objects.

[0050] In an embodiment of the present invention, a photovoltaic module layering device is provided. The photovoltaic module to be layered by the device includes a glass plate, a first EVA adhesive layer, a silicon plate, a second EVA adhesive layer and a back plate in sequence. The glass plate is bonded to the first side of the silicon plate through the first EVA adhesive layer, and the second side of the silicon plate is bonded to the back plate through the second EVA adhesive layer.

[0051] It should be noted that, when the device is in use, only the first EVA adhesive layer and / or the second EVA adhesive layer are heated and separated, thereby obtaining the separated glass plate and silicon plate.

[0052] See also Figure 1 The photovoltaic module delamination apparatus includes at least a machine tool 10, a conveyor unit 1, a preheating assembly 8, a cutting unit, and a separation auxiliary assembly. The photovoltaic module delamination apparatus may also include a control system, which includes a processor. A gantry is located on top of the machine tool 10, with its ends fixedly connected to the sides of the machine tool top. The gantry is a bridge-like structure.

[0053] The preheating assembly 8 is mounted on the inner top of the gantry and is used to irradiate and heat the photovoltaic modules 7 located below the gantry. This irradiation and heating of the photovoltaic modules 7 causes the first and second EVA adhesive layers within the modules 7 to melt and soften to a certain extent, making it easier to separate the first and second EVA adhesive layers from the glass or silicon sheets during cutting and separation. This reduces wear on the glass and silicon sheets by the cutting tool and improves the integrity of the silicon and glass sheets during recycling. The preheating assembly 8 can preheat the EVA layers to a specific temperature range to facilitate delamination.

[0054] See also Figure 1 and Figure 4 The preheating assembly 8 may include an infrared lamp 81, a lampshade 82, and a temperature sensor 83. The lampshade 82 is mounted on the inner top of the gantry, and the infrared lamp 81 is mounted on the inner top of the lampshade 82. Specifically, the infrared lamp 81 is fixed to the lampshade 82 via a pipe clamp. The temperature sensor 83 is mounted on the inner top of the lampshade 82 to monitor the temperature of the photovoltaic module 7. The preheating assembly 8 uniformly heats the photovoltaic module 7 before cutting. The lampshade 82 is designed to protect the lamp and concentrate infrared radiation to ensure even heat distribution.

[0055] The infrared lamp 81 is a black tube heating lamp. Black tube heating lamps generate heat but do not emit light. Their purpose is to protect the silicon substrates from direct sunlight, which could cause light pollution and improve the quality of silicon substrate recycling. A lampshade 82 surrounds the infrared lamp 81 to concentrate heat and protect it. The lampshade 82 can be customized based on the illumination area of ​​the photovoltaic module 7 and the desired irradiation temperature of 200°C to ensure efficient preheating.

[0056] It should be noted that the above embodiment can melt and soften the first EVA adhesive layer and the second EVA adhesive layer to a certain extent, so that it is easier to separate the first EVA adhesive layer and the second EVA adhesive layer from the glass plate or silicon plate during cutting and separation.

[0057] When the photovoltaic module delamination apparatus includes a control system, the control system's processor, when controlling preheating assembly 8, is configured to obtain the real-time temperature of photovoltaic module 7 via temperature sensor 83 and control the heating frequency of infrared lamp 81 to maintain the real-time temperature within a target temperature range. By regulating the real-time temperature, the EVA adhesive layer is always in an optimal separation state, facilitating subsequent separation operations.

[0058] The beneficial effect of this is that by adjusting the power and irradiation time of the infrared lamp 81, the temperature of the EVA layer can be precisely controlled to ensure that it reaches the optimal softening state. This precise temperature control helps to improve the recovery rate and integrity of the materials after the photovoltaic module 7 is disassembled.

[0059] See also Figure 1 and Figure 3 The cutting unit includes an ultrasonic vibration knife 4 and a set of symmetrical tool fixing frames 42. The two tool fixing frames 42 are respectively installed on the inner sides of the two ends of the gantry. The ultrasonic vibration knife 4 is installed between the two tool fixing frames 42. The ultrasonic vibration knife 4 is used to cut the first EVA adhesive layer of the heated photovoltaic module 7 so that the glass plate and the silicon plate of the photovoltaic module 7 can be separated, or to cut the second EVA adhesive layer of the heated photovoltaic module 7 so that the back plate and the silicon plate of the photovoltaic module 7 can be separated.

[0060] It should be noted that the ultrasonic vibration knife 4 is a cutting tool that cuts through high-frequency vibration, which has the effect of smooth cutting surface and high cutting accuracy. The vibration frequency of the ultrasonic vibration knife 4 is adjustable and is used in conjunction with the preheating component 8 to perform overclocked vibration layering on the EVA layer to adapt to the EVA layer of waste photovoltaic modules with different degrees of damage. For example, the ultrasonic vibration knife 4 generates a small mechanical force at the contact point between the blade and the material through high-frequency vibration, usually between 20kHz and 40kHz. This high-frequency vibration enables the blade to quickly cut the material and achieve a high-precision layering effect. The acceleration generated by the ultrasonic vibration is sufficient to quickly pull the tissue apart and achieve cutting without relying on heat or high mechanical force. Therefore, it is suitable for processing brittle and heat-sensitive materials such as EVA. Although the main function of the ultrasonic vibration knife 4 is mechanical, it will also produce a certain thermal effect during use. This thermal effect is due to the fact that when the high-frequency vibration of the ultrasonic wave is absorbed by the medium, part of the energy is converted into heat energy, resulting in a temperature increase. However, the thermal damage caused by the ultrasonic vibration knife 4 is relatively small, and the temperature brought by the heat generated by the tissue generally does not exceed 80°C. This thermal effect helps to reduce the adhesion of the EVA glue layer to a certain extent, which is more conducive to delamination. The ultrasonic vibration knife will also produce a cavitation effect when working. This effect is due to the ultrasonic energy generating tiny bubbles in the liquid. These bubbles rapidly expand and burst under the action of ultrasonic energy, generating high temperature, high pressure and strong shock waves, which help to shake off the EVA after delamination and complete the task of cutting and delamination. The tool state includes geometric features such as position, corner radius, and tip runout. The elastic modulus of the EVA glue is calculated, and the calculated elastic modulus will be fed back to the processor to adjust the frequency of the ultrasonic vibration knife in real time to ensure cutting efficiency and quality and adapt to changes in the physical properties of the glue layer.

[0061] Please refer to Figure 5 , which is a schematic diagram showing the ultrasonic vibration knife 4 cutting the photovoltaic module 7. During cutting, the ultrasonic vibration knife 4 separates the glass plate and the silicon plate by cutting the first EVA adhesive layer.

[0062] It should be noted that the above embodiment can already cut the EVA adhesive layer so as to separate the back plate and the silicon plate of the photovoltaic module 7 .

[0063] When the photovoltaic module layering device includes a control system, a guide rail 41 is symmetrically mounted on the inner side of the gantry, and a tool holder 42 is slidably mounted on the guide rail 41. A movable structure is provided on the guide rail 41 to enable the tool holder 42 to be raised and lowered. This movable structure can use a conventional drive structure, such as an electric cylinder or hydraulic cylinder. The base of the electric cylinder or hydraulic cylinder is mounted at the bottom of the guide rail 41, and the base of the tool holder 42 is fixed to the output end of the electric cylinder or hydraulic cylinder. The tool holder 42 is raised and lowered by moving the output end of the electric cylinder or hydraulic cylinder. A rotatable locking head 46 is provided on the tool holder 42, and a drive structure is provided within the tool holder 42 to enable the locking head 46 to rotate. Specifically, the drive structure may include a motor mounted within the tool holder 42, with the motor drive end driving the locking head 46 to rotate. The drive structure may also include a rotary cylinder mounted within the tool holder 42, with the rotary cylinder drive end driving the locking head 46 to rotate. The ultrasonic vibration blade 4 is mounted on the locking head 46, and the tool holder 42 is mounted with a visual component 43. The visual component 43 includes a camera and an LED light, both of which are mounted on the tool fixing frame 42 and are used to photograph the ultrasonic vibration knife 4 and the photovoltaic component 7 .

[0064] During the process of aligning the ultrasonic vibrating blade 4, the processor of the control system is configured to: acquire real-time image data of the ultrasonic vibrating blade 4 through the visual component 43, compare the real-time image data with the target image data, determine the real-time tool state of the ultrasonic vibrating blade 4, and determine the real-time angle of the locking head 46 and / or the real-time height of the tool holder 42 based on the real-time tool state of the ultrasonic vibrating blade 4. Maintain the real-time angle of the locking head 46 at the target angle and / or control the real-time height of the tool holder 42 at the target height.

[0065] The beneficial effect of this is that the vision component 43 can accurately align the cutter and set the cutter at the position of the layer to be cut of the photovoltaic module 7. The above operation can be performed during cutting.

[0066] For example, a camera captures a real-time image of the ultrasonic vibrating blade 4, and a processor analyzes the real-time image to obtain first image data. The processor compares the first image data with reference image data. If the angle of the ultrasonic vibrating blade 4 is inconsistent with the reference angle, the drive structure will rotate the locking head 46 until the angle of the ultrasonic vibrating blade 4 is consistent with the reference angle. A camera captures a real-time image of the ultrasonic vibrating blade 4, and the processor analyzes the real-time image to obtain second image data. The processor compares the second image data with the reference image data. If the height of the ultrasonic vibrating blade 4 is inconsistent with the reference height, the movable structure will raise or lower the tool holder 42 until the height of the ultrasonic vibrating blade 4 is consistent with the reference height. The reference height and reference angle here refer to the standard cutting position of the ultrasonic vibrating blade 4 and the photovoltaic module 7, which are obtained through data fusion algorithms and machine learning algorithms using intelligent prediction and adjustment of cutting strategies.

[0067] See also Figure 1 The separation auxiliary component includes a robotic arm and a second vacuum suction cup 5. The mechanical interface of the robotic arm is connected to the second vacuum suction cup 5. The second vacuum suction cup 5 is used to adsorb the glass plate of the photovoltaic component 7 so that the glass plate and the silicon plate are separated after the first EVA adhesive layer is cut, or to adsorb the silicon plate of the photovoltaic component 7 so that the back plate and the silicon plate are separated after the second EVA adhesive layer is cut.

[0068] See also Figure 1 When the photovoltaic module layering device includes a control system, the photovoltaic module layering device further includes: a force sensor 6 , which is installed on the second vacuum suction cup 5 and is used to detect the stress of the second vacuum suction cup 5 .

[0069] When adjusting the vibration frequency and amplitude of the ultrasonic vibration blade 4, the processor of the control system is configured to: obtain real-time stress data of the second vacuum suction cup 5 through the force sensor 6, and determine the real-time stress data of the first EVA adhesive layer or the second EVA adhesive layer based on the real-time stress data of the second vacuum suction cup 5. Determine the real-time elastic modulus of the first EVA adhesive layer based on the real-time stress data of the first EVA adhesive layer. Or determine the real-time elastic modulus of the second EVA adhesive layer based on the real-time stress data of the second EVA adhesive layer. Adjust the vibration frequency and amplitude of the ultrasonic vibration blade 4 in real time based on the real-time elastic modulus of the first EVA adhesive layer or the second EVA adhesive layer. Exemplarily, when the real-time elastic modulus is larger, the vibration frequency and amplitude of the ultrasonic vibration blade 4 are smaller.

[0070] The beneficial effects of this are: the processor of the control system can infer the elastic modulus and other mechanical parameters of the EVA layer through real-time stress data, which is crucial for understanding the stratification behavior of the material; when the processor detects the change in force during the separation process through the force sensor 6, the processor calculates the elastic modulus and other mechanical parameters based on the feedback stress data, and dynamically adjusts the frequency and amplitude of the ultrasonic vibration knife based on the elastic modulus and other mechanical parameters, which can optimize the stratification process and improve the separation efficiency; this adaptive adjustment mechanism can cope with photovoltaic modules with different degrees of damage, ensuring efficient stratification in various situations.

[0071] See also Figure 1 and Figure 2 The conveying unit 1 includes a linear module and a first vacuum suction cup 9. The linear module is mounted on top of the machine tool 10. The first vacuum suction cup 9 is mounted on the moving end of the linear module. The first vacuum suction cup 9 is used to absorb the back panel of the photovoltaic module 7. The first vacuum suction cup 9 is connected to the mechanical interface of the robot arm and directly absorbs the glass panel.

[0072] The linear module can adopt a variety of structures. Here is an example: the linear module includes a ball screw guide 41, a drive motor, and a fixed plate. The ball screw guide 41 and drive motor are mounted on the top of the machine tool 10. The drive motor is connected to the driving end of the ball screw guide 41. The fixed plate is bolted to the moving end of the ball screw guide 41 and fixed to the bottom of the first vacuum suction cup 9. The ball screw guide 41 has a stroke of 500 mm. In addition, the linear module can also adopt a common moving device in the prior art, such as a cylinder-driven slider rail structure.

[0073] Furthermore, the first vacuum cup 9 comprises a cup housing and a plurality of square-shaped suction cup openings made of a high-temperature-resistant material. The advantage of a vacuum cup is that it provides uniform and stable suction force, which is particularly important for smooth, fragile materials such as photovoltaic panels 7. By precisely controlling the vacuum level, the panels are protected from damage due to external forces during transport.

[0074] For example, the first vacuum suction cup 9 is composed of a plurality of suction cup units arranged in an arrangement, and each suction cup unit adopts a "U"-shaped groove plus a small square design, so that the photovoltaic component and the suction cup fit perfectly and the sealing effect is better, ensuring the stability of the photovoltaic component during the cutting process, and the sealing ring material can withstand a high temperature of 200°C, so that the transmission unit can work normally under preheating conditions.

[0075] Through the above specific embodiments, the ultrasonic vibration delamination photovoltaic module device of the present invention can achieve efficient and accurate EVA layer delamination, thereby improving the disassembly efficiency and quality of photovoltaic modules.

[0076] The present invention also provides a control method for a photovoltaic module stratification device, which can be applied to the above-mentioned photovoltaic module stratification device including a control system, and can also be applied to the following photovoltaic module stratification device, which includes: a machine tool 10, a conveying unit 1, a preheating component 8, a cutting unit, a visual component 43, a separation auxiliary component, a processor and a force sensor 6.

[0077] A gantry is mounted on top of the machine tool 10, with its ends fixedly connected to the sides of the machine tool's top. The transfer unit 1 includes a linear module mounted on top of the machine tool 10 and a first vacuum suction cup 9 mounted on the moving end of the linear module. The first vacuum suction cup 9 is used to absorb the backplane of the photovoltaic module 7. The preheating assembly 8 includes an infrared lamp 81, a lampshade 82, and a temperature sensor 83. The lampshade 82 is mounted on the inner top of the gantry, the infrared lamp 81 is mounted on the inner top of the lampshade 82, and the temperature sensor 83 is mounted on the inner top of the lampshade 82. The cutting unit includes an ultrasonic vibrating blade 4 and a symmetrically mounted blade holder 42. A guide rail 41 is symmetrically mounted on the inner side of the gantry. The blade holder 42 is slidably mounted on the guide rail 41. A movable structure is provided on the guide rail 41 to raise and lower the blade holder 42. A rotatable locking head 46 is provided on the blade holder 42. A drive structure is provided within the blade holder 42 to rotate the locking head 46. The ultrasonic vibrating blade 4 is mounted on the locking head 46. A visual component 43 is mounted on the blade holder 42. The visual component 43 includes a camera and an LED light, both mounted on the blade holder 42, for capturing images of the ultrasonic vibrating blade 4 and the photovoltaic panel 7. The separation assist component includes a robotic arm and a second vacuum suction cup 5. The robotic arm's mechanical interface is connected to the second vacuum suction cup 5, which is used to absorb the photovoltaic panel backsheet. A force sensor 6 is mounted on the second vacuum suction cup 5.

[0078] The control method of the photovoltaic module layering device is executed by a processor, and the control method includes step S101, step S102, step S103, step S104, step S105, step S106, step S107, step S108 and step S109.

[0079] Step S101 , controlling the first vacuum suction cup to adsorb the photovoltaic component, and controlling the linear module to drive the photovoltaic component to move to the cutting starting position of the ultrasonic vibration knife.

[0080] Step S102, controlling the black tube heating lamp to heat the photovoltaic module 7, obtaining the real-time temperature of the photovoltaic module 7 through the temperature sensor 83 during the heating process, and controlling the heating frequency of the infrared lamp 81 to keep the real-time temperature within the target temperature range.

[0081] Step S103 , controlling the LED light to illuminate the contact area between the ultrasonic vibration knife 4 and the photovoltaic assembly 7 .

[0082] Step S104, obtain the real-time image data of the ultrasonic vibration knife 4 through the camera, compare the real-time image data with the target image data, determine the real-time angle of the ultrasonic vibration knife 4 and the locking head 46, and control the driving structure so that the real-time angle of the ultrasonic vibration knife 4 and the locking head 46 is the target angle.

[0083] Step S105 , controlling the linear module to drive the photovoltaic assembly to move to the cutting end position of the ultrasonic vibration knife.

[0084] Step S106, during the cutting process, real-time image data of the ultrasonic vibrating knife 4 is obtained through the camera, the real-time image data is compared with the target image data, the real-time tool state of the ultrasonic vibrating knife 4 is determined, the real-time angle of the locking head 46 and / or the real-time height of the tool fixing frame 42 are determined according to the real-time tool state of the ultrasonic vibrating knife 4, the driving structure is controlled so that the real-time angle of the locking head 46 is the target angle and / or the moving structure is controlled so that the real-time height of the tool fixing frame 42 is the target height.

[0085] Step S107: Control the robotic arm to move the second vacuum suction cup 5 to adsorb the glass plate or silicon plate, obtain real-time stress data of the second vacuum suction cup 5 through the force sensor 6, and determine the real-time stress data of the first EVA adhesive layer or the second EVA adhesive layer based on the real-time stress data of the second vacuum suction cup 5.

[0086] Step S108: determining the real-time elastic modulus of the first EVA adhesive layer based on the real-time stress data of the first EVA adhesive layer, or determining the real-time elastic modulus of the second EVA adhesive layer based on the real-time stress data of the second EVA adhesive layer.

[0087] Step S109: adjusting the vibration frequency and amplitude of the ultrasonic vibration blade 4 in real time according to the real-time elastic modulus of the first EVA adhesive layer or the second EVA adhesive layer until the separation of the EVA adhesive layer is completed.

[0088] To facilitate understanding of the technical solution, a complete workflow is provided below:

[0089] For example, in a specific overall embodiment, see Figure 6 The method for ultrasonic vibration delamination of photovoltaic modules includes the following steps:

[0090] 1. Use vacuum suction cups to fix the photovoltaic modules to ensure the stability of the modules.

[0091] 2. Preheat the EVA adhesive through the infrared preheating system to achieve appropriate flexibility and temperature conditions.

[0092] 3. Use ultrasonic vibration knife to perform precise cutting, and monitor the cutting status in real time through force sensor and vision system.

[0093] 4. Adaptively adjust the working parameters of the ultrasonic vibration knife according to real-time data, and make fine adjustments through the PID controller.

[0094] 5. Apply data fusion algorithms and machine learning algorithms to intelligently predict and adjust cutting strategies.

[0095] 6. In the closed-loop control system, real-time feedback adjustment ensures the stability and accuracy of the cutting process.

[0096] 7. Through effective scheduling algorithms, rationally arrange the work of each link to achieve efficient stratification.

[0097] For example, in terms of algorithm optimization, a data fusion algorithm integrates data from force sensor 6, vision component 43, and temperature sensor 83 to form a high-precision state estimate, improving the system's understanding of the current layer state. Simultaneously, machine learning algorithms, such as reinforcement learning, are applied to train models using historical data to predict optimal cutting parameters and strategies under different conditions, enhancing the system's intelligence.

[0098] A PID controller is used during the cutting process to optimize the system's response speed and steady-state accuracy by adjusting the proportional, integral, and differential parameters. The fixed frame that holds the cutting tool can rotate, and the blade edge is adjusted using a visual aid to facilitate finding the optimal cutting angle. Regarding the feedback control mechanism, a closed-loop control system is established. By monitoring the data from the force sensor 6 and the visual component 43 in real time, the operation of the ultrasonic vibrating blade 4 is adjusted to ensure the stability and accuracy of the cutting process. Furthermore, a PID controller is used to manage the frequency and amplitude of the ultrasonic vibrating blade, optimizing the system's response speed and steady-state accuracy. Regarding overall system optimization, the collaborative working mechanism of each subsystem (the second vacuum chuck 5, the preheating component, the ultrasonic vibrating blade 4, and the robotic arm) is optimized to ensure the immediacy and accuracy of information transmission and status feedback. Furthermore, an effective scheduling algorithm is designed and determined based on actual conditions. This scheduling algorithm allows for a rational arrangement of work order and time, improving the efficiency of the entire delamination process, reducing energy consumption, and minimizing material loss. The device utilizes adaptive control theory, dynamically adjusting the operating frequency and amplitude of the ultrasonic vibrating blade 4 by monitoring the feedback from the force sensor 6 in real time. This dynamic adjustment adapts to the characteristics of different EVA layers, optimizes cutting parameters, and improves delamination efficiency and quality. It also utilizes Model Predictive Control (MPC) technology to pre-calculate optimal control inputs based on a mathematical model of the PV module delamination process. This helps address system latency and uncertainty, ensuring precise control in a changing environment.

[0099] It should be understood that the specific embodiments described herein are only used to explain this application and are not used to limit it. Based on the embodiments provided in this application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0100] Obviously, the accompanying drawings are merely examples or embodiments of the present application. A person skilled in the art can also apply the present application to other similar situations based on these drawings without inventive effort. Furthermore, it is understandable that, although the work involved in this development process may be complex and lengthy, certain design, manufacturing, or production changes based on the technical content disclosed in this application are merely routine technical means for a person skilled in the art and should not be considered to constitute a deficiency in the disclosure of the present application.

Claims

1. A photovoltaic module layering device, wherein the photovoltaic module comprises a glass plate, a first EVA adhesive layer, a silicon plate, a second EVA adhesive layer, and a back plate in sequence, wherein the first side of the silicon plate is bonded to the back plate via the first EVA adhesive layer, and the second side of the silicon plate is bonded to the back plate via the second EVA adhesive layer, characterized in that: The layered device includes: A machine tool (10) is provided with a gantry on its top, and two ends of the gantry are respectively fixedly connected to two sides of the top of the machine tool; A conveying unit (1) comprising a linear module and a first vacuum suction cup (9), wherein the linear module is mounted on the top of a machine tool (10), and the first vacuum suction cup (9) is mounted on a movable end of the linear module, and the first vacuum suction cup (9) is used to absorb a back plate of a photovoltaic module (7); A preheating assembly (8) is mounted on the inner top of the gantry and is used to irradiate and heat the photovoltaic assembly (7) below the gantry; A cutting unit comprising an ultrasonic vibration knife (4) and a set of symmetrical knife fixing frames (42), wherein the two knife fixing frames (42) are respectively mounted on the inner sides of both ends of the gantry frame, and the ultrasonic vibration knife (4) is mounted between the two knife fixing frames (42). The ultrasonic vibration knife (4) is used to cut the first EVA adhesive layer of the heated photovoltaic module (7) so that the glass plate and the silicon plate of the photovoltaic module (7) can be separated, or to cut the second EVA adhesive layer of the heated photovoltaic module (7) so that the back plate and the silicon plate of the photovoltaic module (7) can be separated. The separation auxiliary component comprises a mechanical arm and a second vacuum suction cup (5), wherein the mechanical interface of the mechanical arm is connected to the second vacuum suction cup (5), and the second vacuum suction cup (5) is used to absorb the glass plate of the photovoltaic module (7) so that the glass plate and the silicon plate are separated after the first EVA adhesive layer is cut, or to absorb the silicon plate of the photovoltaic module (7) so that the back plate and the silicon plate are separated after the second EVA adhesive layer is cut.

2. The photovoltaic module layering device according to claim 1, characterized in that: The photovoltaic module layering device further comprises: a force sensor (6) mounted on the second vacuum chuck (5) and configured to detect stress of the second vacuum chuck (5); A processor configured to: Acquiring real-time stress data of the second vacuum suction cup (5) through a force sensor (6), and determining real-time stress data of the first EVA adhesive layer or the second EVA adhesive layer based on the real-time stress data of the second vacuum suction cup (5); Determine the real-time elastic modulus of the first EVA adhesive layer according to the real-time stress data of the first EVA adhesive layer; or determine the real-time elastic modulus of the second EVA adhesive layer according to the real-time stress data of the second EVA adhesive layer; The vibration frequency and vibration amplitude of the ultrasonic vibration knife (4) are adjusted in real time according to the real-time elastic modulus of the first EVA adhesive layer or the second EVA adhesive layer.

3. The photovoltaic module layering device according to claim 1, characterized in that: The photovoltaic module layering device also includes a processor, a guide rail (41) is symmetrically installed on the inner side of the gantry, a tool fixing frame (42) is slidably installed on the guide rail (41), a moving structure for lifting the tool fixing frame (42) is provided on the guide rail (41), a rotatable locking head (46) is provided on the tool fixing frame (42), a driving structure for rotating the locking head (46) is provided in the tool fixing frame (42), an ultrasonic vibration knife (4) is installed on the locking head (46), and a visual component (43) is installed on the tool fixing frame (42); The processor is configured to: Acquiring real-time image data of the ultrasonic vibration knife (4) through a visual component (43), comparing the real-time image data with target image data, determining a real-time tool state of the ultrasonic vibration knife (4), and determining a real-time angle of the locking head (46) and / or a real-time height of the tool fixing frame (42) based on the real-time tool state of the ultrasonic vibration knife (4); The real-time angle of the locking head (46) is maintained at a target angle and / or the real-time height of the tool holder (42) is controlled to be a target height.

4. The photovoltaic module layering device according to claim 3, characterized in that: The driving structure includes a motor, which is installed inside the tool fixing frame (42), and the motor driving end drives the locking head (46) to rotate.

5. The photovoltaic module layering device according to claim 3, characterized in that: The visual component (43) includes a camera and an LED light, both of which are mounted on the tool fixing frame (42) and are used to photograph the ultrasonic vibration knife (4) and the photovoltaic component (7).

6. The photovoltaic module layering device according to claim 1, characterized in that: The first vacuum suction cup (9) comprises a suction cup shell and a plurality of square suction cup openings, wherein the square suction cup openings are made of a high temperature resistant material.

7. The photovoltaic module layering device according to claim 1, characterized in that: The preheating assembly (8) includes an infrared lamp tube (81), a lampshade (82) and a temperature sensor (83), wherein the lampshade (82) is mounted on the inner top of the gantry, the infrared lamp tube (81) is mounted on the inner top of the lampshade (82), and the temperature sensor (83) is mounted on the inner top of the lampshade (82) for monitoring the temperature of the photovoltaic assembly (7); The photovoltaic module layering device further includes a processor configured to: The real-time temperature of the photovoltaic assembly (7) is obtained through the temperature sensor (83), and the heating frequency of the infrared lamp (81) is controlled to keep the real-time temperature within the target temperature range.

8. The photovoltaic module layering device according to claim 7, characterized in that: The infrared lamp (81) is a black tube heating lamp.

9. The photovoltaic module layering device according to claim 1, characterized in that: The linear module comprises a ball screw guide rail (41), a drive motor and a fixed plate. The ball screw guide rail (41) and the drive motor are mounted on the top of the machine tool (10). The drive motor is connected to the drive end of the ball screw guide rail (41). The fixed plate is mounted on the moving end of the ball screw guide rail (41). The fixed plate is fixed to the bottom of the first vacuum suction cup (9).

10. A control method for a photovoltaic module layering device, characterized in that: The photovoltaic module layering device comprises: A machine tool (10) is provided with a gantry on the top of the machine tool (10), and two ends of the gantry are respectively fixedly connected to two sides of the top of the machine tool; A conveying unit (1) comprising a linear module and a first vacuum suction cup (9), wherein the linear module is mounted on the top of a machine tool (10), and the first vacuum suction cup (9) is mounted on a movable end of the linear module, and the first vacuum suction cup (9) is used to absorb a back plate of a photovoltaic module (7); A preheating assembly (8), the preheating assembly (8) comprising an infrared lamp tube (81), a lampshade (82) and a temperature sensor (83), the lampshade (82) being mounted on the inner top of the gantry, the infrared lamp tube (81) being mounted on the inner top of the lampshade (82), and the temperature sensor (83) being mounted on the inner top of the lampshade (82); A cutting unit comprises an ultrasonic vibration knife (4) and a symmetrically mounted knife fixing frame (42); a guide rail (41) is symmetrically mounted on the inner side of a gantry frame; the knife fixing frame (42) is slidably mounted on the guide rail (41); a moving structure for lifting the knife fixing frame (42) is provided on the guide rail (41); a rotatable locking head (46) is provided on the knife fixing frame (42); a driving structure for rotating the locking head (46) is provided in the knife fixing frame (42); the ultrasonic vibration knife (4) is mounted on the locking head (46); and a visual component (43) is mounted on the knife fixing frame (42); The visual component (43) includes a camera and an LED light, both of which are mounted on a tool fixing frame (42) and are used to photograph the ultrasonic vibration knife (4) and the photovoltaic component (7); A separation auxiliary component comprises a mechanical arm and a second vacuum suction cup (5), wherein the mechanical interface of the mechanical arm is connected to the second vacuum suction cup (5), and the second vacuum suction cup (5) is used to adsorb the photovoltaic panel back plate; processor; A force sensor (6), the force sensor (6) is mounted on the second vacuum suction cup (5); The control method includes: Step S101, controlling the first vacuum suction cup to adsorb the photovoltaic module, and controlling the linear module to drive the photovoltaic module to move to the cutting starting position of the ultrasonic vibration knife; Step S102, controlling the black tube heating lamp to heat the photovoltaic assembly (7), obtaining the real-time temperature of the photovoltaic assembly (7) through the temperature sensor (83) during the heating process, and controlling the heating frequency of the infrared lamp (81) to keep the real-time temperature within the target temperature range; Step S103, controlling the LED light to illuminate the contact area between the ultrasonic vibration knife (4) and the photovoltaic module (7); Step S104, obtaining real-time image data of the ultrasonic vibration knife (4) through a camera, comparing the real-time image data with the target image data, determining the real-time angle of the ultrasonic vibration knife (4) and the locking head (46), and controlling the driving structure so that the real-time angle of the ultrasonic vibration knife (4) and the locking head (46) is the target angle; Step S105, controlling the linear module to drive the photovoltaic module to move to the cutting end position of the ultrasonic vibration knife; Step S106, during the cutting process, real-time image data of the ultrasonic vibration knife (4) is obtained through a camera, the real-time image data is compared with the target image data, the real-time tool state of the ultrasonic vibration knife (4) is determined, the real-time angle of the locking head (46) and / or the real-time height of the tool fixing frame (42) are determined according to the real-time tool state of the ultrasonic vibration knife (4), and the driving structure is controlled so that the real-time angle of the locking head (46) is the target angle and / or the moving structure is controlled so that the real-time height of the tool fixing frame (42) is the target height; Step S107, controlling the robotic arm to move the second vacuum suction cup (5) to adsorb the glass plate or the silicon plate, obtaining real-time stress data of the second vacuum suction cup (5) through the force sensor (6), and determining the real-time stress data of the first EVA adhesive layer or the second EVA adhesive layer based on the real-time stress data of the second vacuum suction cup (5); Step S108, determining the real-time elastic modulus of the first EVA adhesive layer according to the real-time stress data of the first EVA adhesive layer; or determining the real-time elastic modulus of the second EVA adhesive layer according to the real-time stress data of the second EVA adhesive layer; Step S109, adjusting the vibration frequency and vibration amplitude of the ultrasonic vibration knife (4) in real time according to the real-time elastic modulus of the first EVA adhesive layer or the second EVA adhesive layer until the separation of the EVA adhesive layer is completed.

Images