A system and method for detecting the profile of a photovoltaic module

Abstract

The application relates to a forming structure appearance detection system and method of a photovoltaic module, and belongs to the technical field of diode detection. The system comprises a rack, a conveying assembly arranged on the rack and used for conveying the photovoltaic module, and a size detection assembly, a hole type detection assembly and a visual appearance detection assembly sequentially arranged on the rack along the conveying direction of the photovoltaic module. The size detection assembly is used for detecting whether the size of the photovoltaic module meets the standard, the hole type detection assembly is used for judging whether the holes arranged on the photovoltaic module meet the standard, and the visual appearance detection assembly is used for judging whether the appearance of the photovoltaic module meets the standard. The system further comprises a controller and a screening assembly. The controller is used for controlling the screening assembly to screen the photovoltaic modules meeting the standard and not meeting the standard based on the detection results of the size detection assembly, the hole type detection assembly and the visual appearance detection assembly. The application has the effects of improving the detection efficiency and the detection accuracy of the appearance detection of the photovoltaic module.

Description

Technical Field

[0001] This application relates to the field of diode testing technology, and in particular to a system and method for testing the shape of a photovoltaic module's molded structure. Background Technology

[0002] During the use of solar cell modules, some areas may be shaded, thus consuming energy and generating heat as a load. This is known as the hot spot effect, which can severely damage the module. A photovoltaic module (i.e., a bypass diode) is a diode connected in parallel across the two ends of a solar cell module to help prevent damage from the hot spot effect. After manufacturing, these diodes typically undergo visual inspection, verifying their dimensions, surface defects, and whether the printed markings meet standards. Currently, this verification is usually done manually, but since photovoltaic modules are generally mass-produced, this method is not only inefficient but also prone to human error, thus requiring improvement. Summary of the Invention

[0003] To improve the efficiency and accuracy of appearance inspection of photovoltaic modules, this application provides a system and method for inspecting the shape of the formed structure of photovoltaic modules.

[0004] In a first aspect, this application provides a photovoltaic module forming structure shape inspection system, including a frame, on which a conveying component for conveying photovoltaic modules is disposed, and a size detection component, a hole shape detection component, and a visual appearance inspection component are sequentially disposed along the conveying direction of the photovoltaic modules; the size detection component is used to detect whether the size of the photovoltaic module meets the standard, the hole shape detection component is used to determine whether the holes opened on the photovoltaic module meet the standard, and the visual appearance inspection component is used to determine whether the appearance of the photovoltaic module meets the standard; it also includes a controller and a screening component, the controller being used to control the screening component to screen photovoltaic modules that meet the standard and those that do not based on the detection results of the size detection component, the hole shape detection component, and the visual appearance inspection component.

[0005] By adopting the above technical solution, multiple inspection components such as size inspection component, hole shape inspection component and visual appearance inspection component are set up to realize diversified and comprehensive quality inspection of multi-photovoltaic module finished products. The photovoltaic modules are automatically transported to all the aforementioned components for inspection by a conveying component. The above inspection components are used to automatically screen out good products and defective products after each inspection, replacing manual quality inspection with automated machinery, thereby improving quality inspection efficiency and accuracy.

[0006] Optionally, the conveying assembly includes a movable ring rotatably connected to the frame, a rotating component for driving the movable ring to rotate, a plurality of adsorption components distributed circumferentially along the movable ring, a lifting component for driving the movable ring to rise and fall, and a first conveyor belt for supplying photovoltaic modules; the adsorption components are used to adsorb photovoltaic modules, and the adsorption components can rotate to above the end of the first conveyor belt during the rotation of the movable ring, and then adsorb the photovoltaic modules at the end of the conveyor belt by the descent action of the lifting component; the size detection component, the aperture detection component, and the visual appearance detection component are used to detect the photovoltaic modules adsorbed by the adsorption components.

[0007] By adopting the above technical solution, the photovoltaic module to be tested is conveyed to the lower part of the rotating path of the adsorption component using the first conveyor belt, so that the adsorption component can move down under the drive of the lifting component and adsorb the photovoltaic module at the end of the conveyor belt. As the moving ring rotates, all adsorption components on the moving ring can adsorb a photovoltaic module, thereby realizing uninterrupted detection of the size detection component, hole type detection component and visual appearance detection component, and improving detection efficiency.

[0008] Optionally, both the size detection component and the screening component are controlled by a controller. The size detection component includes a first detection platform, a first docking rod, a first spring, and a first pressure sensor. Each adsorption element is correspondingly connected to a relief spring and is slidably connected to the movable ring along the lifting direction of the lifting element via the corresponding relief spring. The frame is also provided with a docking ring. The lifting element is used to drive the movable ring and the docking ring to rise and fall together. The first detection platform has a slot for inserting compliant photovoltaic modules. The distance by which the lifting element drives the adsorption element to descend is sufficient to allow the compliant photovoltaic modules adsorbed by the adsorption element to move down and be inserted into the slot.

[0009] The first docking rod is slidably connected to the docking ring by a first spring, and the sliding direction of the first docking rod relative to the docking ring is parallel to the lifting direction of the movable ring and the docking ring. When the target adsorption component moves above the first detection stage, the first docking rod is located above the target adsorption component, wherein the target adsorption component is any adsorption component.

[0010] When the first spring and the relief spring are not deformed, the distance between the lower end of the first docking rod and the top of the target adsorption component is not greater than the slot depth. The first pressure sensor is located at the other end of the first docking rod to detect the pressure exerted by the first docking rod on the first pressure sensor when the first docking rod moves upward relative to the docking ring. The controller is used to obtain the detection result of the first pressure sensor and, when the detection result is a defective product, control the screening component to discharge the photovoltaic module adsorbed by the adsorption component above the first detection table.

[0011] By adopting the above technical solution, only photovoltaic modules that meet the size requirements can be inserted into the slot. For photovoltaic modules that are too large to be inserted into the slot, the photovoltaic module will be blocked by the upper surface of the first detection platform and will not be able to move down. This will cause the adsorption component to move up and push against the first docking rod, so that the first docking rod moves up and presses against the first pressure sensor. This will allow the first pressure sensor to detect the corresponding pressure. At this time, the controller can control the first screening component to discharge the photovoltaic modules (i.e. defective products) adsorbed by the adsorption component above the first detection platform.

[0012] Optionally, the aperture detection component is controlled by a controller. The aperture detection component includes a second detection stage, a pin disposed on the second detection stage, a second spring and a second docking rod disposed on the docking ring, and a second pressure sensor disposed at the end of the second docking rod. The lifting component drives the adsorption component to descend a distance that satisfies the following conditions: the qualified photovoltaic module adsorbed by the adsorption component moves down, and the pin penetrates the preset hole of the qualified photovoltaic module.

[0013] The second docking rod is slidably connected to the docking ring by the second spring, and the sliding direction of the second docking rod relative to the docking ring is parallel to the lifting direction of the movable ring and the docking ring. When the target adsorption component moves above the second detection stage, the second docking rod is located above the target adsorption component.

[0014] When the second spring and the relief spring are not deformed, the distance between the lower end of the second docking rod and the top of the target adsorption component is not greater than the length of the pin. The second pressure sensor is located at the other end of the second docking rod to detect the pressure exerted by the second docking rod on the second pressure sensor when the second docking rod moves upward relative to the docking ring. The controller is used to obtain the detection result of the second pressure sensor and, when the detection result is a defective product, control the screening component to discharge the photovoltaic module adsorbed by the adsorption component above the second detection table.

[0015] By adopting the above technical solution, for photovoltaic modules that are smaller than the standard size, or whose preset holes are not up to standard or are not through (i.e., defective products), when such defective products are sucked up to the top of the second detection platform by the adsorption component and moved down by the lifting component, the ejector pin will not be able to insert into the preset hole. At this time, the defective product will be pushed by the ejector pin, causing the adsorption component to move up and the second docking rod to move up. This allows the second pressure sensor to detect the resistance from the upward movement of the second docking rod, thereby causing the controller to control the second screening component to discharge the photovoltaic modules adsorbed by the adsorption component above the second detection platform, thus achieving the removal of the defective products.

[0016] Optionally, the visual appearance inspection component includes a third inspection table, a camera device, and several light sources; the camera device is located around the third inspection table to capture an inspection image with an image of the upper surface of the third inspection table; several light sources are located around the third inspection table and illuminate the third inspection table from a preset angle, and when the photovoltaic module is located on the third inspection table, the photovoltaic module will be illuminated by the light source and cast a shadow on the surface of the third inspection table, and the inspection image captured by the camera device includes the shadow; the controller is used to acquire the inspection image, compare the inspection image with a preset reference image, and control the screening component to discharge the photovoltaic module on the third inspection table when the comparison result is a defective product; wherein, the reference image includes the shadow of the compliant photovoltaic module on the third inspection table irradiated by the light source.

[0017] By adopting the above technical solution, since the structure of the photovoltaic module is not planar and involves bending parts, and since the shooting angle of the camera equipment is single, the image captured by it is not easy to fully show the bending parts of the photovoltaic module and the degree of bending. Therefore, this application proposes to use the light and shadow formed by the light source illuminating the photovoltaic module as a comparison element. In the process of comparing images, the projected light and shadow are further used to reflect the degree of bending of the photovoltaic module, thereby optimizing the quality inspection effect of the appearance of the photovoltaic module.

[0018] Optionally, the detection images include the light and shadow images corresponding to each light source individually illuminating the photovoltaic module on the third detection platform. The controller is used to acquire all the light and shadow images and, based on all the light and shadow images, verify whether the photovoltaic module has shifted during the process of being illuminated and photographed by different light sources. If it has shifted, all the light and shadow images are corrected and then compared with a preset reference image. If the comparison is inconsistent, the comparison result is determined to be a defective product. The preset reference image includes the light and shadow images corresponding to compliant photovoltaic modules.

[0019] By adopting the above technical solution, considering that the photovoltaic module may shift during the process of being illuminated and photographed by a single light source, resulting in inconsistencies between the light and shadow images and the preset reference images, which may lead to misjudgments of whether the product is good or not and increase the defect rate, this application adds a verification operation to the comparison process, corrects the light and shadow images corresponding to the shifted photovoltaic modules, and then uses the corrected light and shadow images to re-compare and judge, thereby improving the detection accuracy.

[0020] Optionally, all the light sources satisfy the following: for each light source illuminating a qualified photovoltaic module individually, there exists a light and shadow image with a shared shadow surface in other light and shadow images; the controller also pre-stores associated light and shadow images and their corresponding reference shadow surfaces; the associated light and shadow images refer to light and shadow images with a reference shadow surface and an associated relationship, and the reference shadow surface is a shared shadow surface among the light and shadow images corresponding to the qualified photovoltaic modules pre-stored by the controller;

[0021] The controller is used to verify whether there is a common shadow surface in the related light and shadow images after acquiring the light and shadow images. If there is no common shadow surface or the existing common shadow surface is inconsistent with the corresponding reference shadow surface, the photovoltaic module offset is verified.

[0022] By adopting the above technical solution, the common shadow surface produced by the light and shadow images taken when any two light sources are irradiated individually can be directly found, and the common shadow surface is compared with the corresponding reference shadow surface to verify whether the photovoltaic module is offset.

[0023] Optionally, the controller is used to determine whether the degree of deformation of the photovoltaic module corresponding to the light and shadow image is within a preset deformation tolerance range when it is determined that the light and shadow image is inconsistent with the preset reference image, based on the different deformation types and the shadow surface corresponding to the degree of deformation of each deformation type. If not, the comparison result is determined to be a defective product, otherwise it is a good product.

[0024] By adopting the above technical solution, if the deformation of the photovoltaic module is within the preset deformation tolerance range, it is considered that the deformation type and degree of the photovoltaic module do not affect actual use. This optimizes the judgment scheme and indirectly improves the yield rate.

[0025] Optionally, the screening assembly includes a pull rope, a limiting spring, and a motor, each corresponding to an adsorption element; the adsorption element is connected to the movable ring by sliding radially along the movable ring via the limiting spring; one end of the pull rope is connected to the adsorption element, and the other end is connected to the corresponding motor drive end; the motor is mounted on the movable ring and controlled by a controller; the size detection assembly, the aperture detection assembly, and the visual appearance detection assembly each have a defective product recovery track, which is located below the path of the corresponding adsorption element as it slides radially relative to the movable ring.

[0026] By adopting the above technical solution, the controller starts the motor to wind the pull rope, causing the limiting component to move above the corresponding defective product recycling track under the pull of the pull rope. Then, the motor is paused for a specified time and the adsorption component is controlled to release its adsorption on the photovoltaic module. During this period, the limiting spring deforms. After pausing for the specified time, the motor is controlled to restart and reverse to release the wound pull rope, thereby causing the adsorption component to reset under the elastic force of the corresponding limiting spring.

[0027] Secondly, this application also discloses a method for detecting the shape of a photovoltaic module's molded structure, applied to the photovoltaic module's shape detection system as described in the first aspect, comprising:

[0028] The photovoltaic module to be tested is sequentially transported to the size detection component, aperture detection component, and visual appearance inspection component using the transport component;

[0029] The photovoltaic module is inspected for size compliance using a size inspection component; the photovoltaic module is inspected for hole size and continuity using a hole type inspection component; and the photovoltaic module is inspected for defects using a visual appearance inspection component.

[0030] The controller acquires the detection results from the size detection component, aperture detection component, and visual appearance detection component, and controls the screening component to screen out photovoltaic modules that meet or fail the detection standards.

[0031] In summary, this application includes the following beneficial technical effects:

[0032] By setting up multiple inspection components such as size inspection components, hole shape inspection components, and visual appearance inspection components, diversified and comprehensive quality inspection of finished photovoltaic modules can be achieved. The photovoltaic modules are automatically transported to all the aforementioned components for inspection in sequence using a conveying component. After each inspection, the above inspection components are used to automatically screen out good and bad products, replacing manual quality inspection with automated machinery, thereby improving quality inspection efficiency and accuracy. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the shape inspection system for the formed structure of a photovoltaic module disclosed in Embodiment 1 of this application.

[0034] Figure 2 This is an enlarged schematic diagram of Embodiment 1 of this application, illustrating the structure of the size detection component and the hole type detection component.

[0035] Figure 3 This is a structural block diagram of a photovoltaic module molding structure shape inspection system disclosed in Embodiment 1 of this application.

[0036] Figure 4This is a schematic diagram of the shape inspection system for the formed structure of a photovoltaic module disclosed in Embodiment 2 of this application.

[0037] Figure 5 yes Figure 4 Enlarged diagram of point A in the middle.

[0038] Explanation of reference numerals in the attached drawings: 1. Frame; 11. Support column; 12. Docking ring; 2. Conveying assembly; 21. First conveyor belt; 22. Movable ring; 221. Support rod; 222. Slider; 23. Rotating component; 24. Lifting component; 241. First cylinder; 242. Second cylinder; 25. Adsorption component; 251. Connecting rod; 252. Relief spring; 3. Dimension detection assembly; 31. First detection table; 311. Slot; 32. First docking rod; 33. First 34. Spring; 4. First pressure sensor; 5. Hole type detection assembly; 6. Second detection stage; 7. Ejector pin; 8. Second spring; 9. Second docking rod; 10. Second pressure sensor; 11. Visual appearance inspection assembly; 12. Third detection stage; 13. Camera equipment; 14. Light source; 15. Controller; 16. Screening assembly; 17. Second conveyor belt; 18. Third conveyor belt; 19. Pull rope; 20. Limit spring; 21. Motor; 22. Photovoltaic module. Detailed Implementation

[0039] The following is in conjunction with the appendix Figure 1-5 This application will be described in further detail.

[0040] Example 1

[0041] Embodiment 1 of this application discloses a system for inspecting the shape of a photovoltaic module's molded structure. (Refer to...) Figure 1 and Figure 2 The photovoltaic module forming structure shape inspection system includes a frame 1, on which a conveying assembly 2 for conveying photovoltaic modules 8 is mounted. The frame 1 also includes a size inspection assembly 3, a hole type inspection assembly 4, and a visual appearance inspection assembly 5, arranged sequentially along the conveying direction of the photovoltaic module 8 by the conveying assembly 2. Specifically, the size inspection assembly 3 is used to detect whether the dimensions of the photovoltaic module 8 meet the standards, the hole type inspection assembly 4 is used to detect whether the holes drilled on the photovoltaic module 8 meet the standards, and the visual appearance inspection assembly is used to determine whether the appearance of the photovoltaic module 8 meets the standards.

[0042] Reference Figure 1 and Figure 2The conveying assembly 2 specifically includes a first conveyor belt 21, a movable ring 22, a rotating component 23, a lifting component 24, and several adsorption components 25. A support column 11 is rotatably connected to the frame 1. The rotating component 23 can be a motor, and its drive shaft is connected to the end of the support column 11 to drive the support column 11 to rotate. The movable ring 22 is slidably connected to the support column 11 along its height direction, and the support column 11 is located at the center of the movable ring 22. The lifting component 24 includes a first cylinder 241, which is connected to the support column 11, and its drive end is connected to the movable ring 22 to drive the movable ring 22 to slide relative to the support column 11 in the height direction. The movable ring 22 has several support rods 221 along its circumference, each support rod 221 corresponding to an adsorption component 25, and the adsorption component 25 is connected to the end of the corresponding support rod 221. The adsorption component 25 specifically includes a connecting rod 251, a relief spring 252, and a vacuum suction cup. The relief spring 252 is sleeved on the connecting rod 251, with one end connected to the connecting rod 251 and the other end connected to the corresponding support rod 221. The vacuum suction cup is located at the lower end of the connecting rod 251 and is connected to a vacuum pump via an air pipe. Therefore, the conveying direction of the conveying component 2 to the photovoltaic module 8 is the same as the rotation direction of the adsorption component 25 around the support column 11. Figure 1 The direction indicated by the dashed arrow.

[0043] The first conveyor belt 21 is located on one side of the support column 11, and the adsorption member 25 can rotate to the top of the end of the first conveyor belt 21 as the movable ring 22 and the support column 11 rotate. At this time, when the movable ring 22 is driven to move down by the first cylinder 241, the adsorption member 25, which has rotated to the top of the end of the first conveyor belt 21, can adsorb the photovoltaic module 8 at the end of the first conveyor belt 21.

[0044] Reference Figure 1 and Figure 2 The size detection component 3 includes a first detection platform 31, a first docking rod 32, a first spring 33, and a first pressure sensor 34. A slot 311 is provided on the first detection platform 31, and the size of the slot 311 is such that only a single compliant photovoltaic module 8 can be inserted into the slot. A docking ring 12 is also fixedly connected to the frame 1, located above the movable ring 22. The lifting component 24 also includes a second cylinder 242 for driving the docking ring 12 to rise and fall together with the movable ring 22. The driving end of the second cylinder 242 is connected to the movable ring 22. Synchronous rising and falling of the movable ring 22 and the docking ring 12 can be achieved by simultaneously opening and closing the first cylinder 241 and the second cylinder 242.

[0045] The first spring 33 is sleeved on the first docking rod 32, and the first docking rod 32 is slidably connected to the movable ring 22 through the first spring 33. The sliding direction of the first docking rod 32 relative to the docking ring 12 is parallel to the sliding direction of the connecting rod 251 relative to the movable ring 22 under the yielding action of the yielding spring 252. This sliding direction is the vertical direction disclosed in the embodiments of this application, that is, the extension and retraction direction of the driving ends of the first cylinder 241 and the second cylinder 242.

[0046] The first pressure sensor 34 is connected to the docking ring 12 and is located at the upper end of the first docking rod 32. The first detection platform 31 is located directly below the first docking rod 32. The connecting rod 251 can rotate to the position directly below the first docking rod 32 as the movable ring 22 rotates, that is, between the first docking rod 32 and the first detection platform 31. At this time, both the first spring 33 and the relief spring 252 are deformed. The lower end of the first docking rod 32 is in contact with the upper end of the connecting rod 251, and the upper end of the first docking rod 32 is in contact with the corresponding first pressure sensor 34.

[0047] At this time, the first cylinder 241 and the second cylinder 242 start simultaneously, driving the first docking rod 32 and the connecting rod 251 to move downwards, so that the photovoltaic module 8 adsorbed by the adsorption member 25 moves downwards onto the first detection platform 31. If the size of the photovoltaic module 8 meets the standard, it will be successfully inserted into the slot 311. If the size of the photovoltaic module 8 does not meet the standard, it will not be able to be inserted into the slot 311. At this time, the upper surface of the first detection platform 31 near the slot 311 will block the downward movement of the photovoltaic module 8, causing the photovoltaic module 8 to move upwards relative to the first detection platform 31. This causes the connecting rod 251 to move upward, at which point the relief spring 252 is compressed. The upward movement of the connecting rod 251 will push the first docking rod 32 upward, so that the first docking rod 32 moves upward and comes into contact with the first pressure sensor 34, thereby allowing the first pressure sensor 34 to detect the pressure from the first docking rod 32. When the driving ends of the first cylinder 241 and the second cylinder 242 move upward and reset, the first docking rod 32 and the connecting rod 251 will slide back to their original positions under the elastic force of the first spring 33 and the relief spring 252, releasing the pressure on the first pressure sensor 34.

[0048] Reference Figure 1 , Figure 2 and Figure 3In addition, the first pressure sensor 34 is electrically connected to the controller 6, and the controller 6 is electrically connected to the warning light. The warning light is set one-to-one with the first docking rod 32 and is connected to the docking ring 12 near the corresponding first docking rod 32. The controller 6 is used to control the warning light to light up when the pressure detected by the first pressure sensor 34 is equal to the preset pressure value (i.e. the pushing force when the first docking rod 32 pushes the first pressure sensor 34 upward) so as to remind the inspection personnel that the photovoltaic module 8 on the first inspection table 31 corresponding to the current warning light is a defective product with substandard size.

[0049] And because the external structure of photovoltaic module 8 is as follows Figure 2 Due to the irregular structure shown, there are several size detection components 3 in this embodiment. Each size detection component 3 corresponds to a different slot 311 structure; that is, each slot 311 corresponding to a size detection component 3 is used for insertion into different areas of the photovoltaic module 8. For example, Figure 2 The document provides three types of slots 311, one of which is for insertion only at the end of the photovoltaic module 8, another slot 311 whose length is consistent with the length of the compliant photovoltaic module 8, for detecting whether the length of the photovoltaic module 8 meets the standard, and the third slot 311 whose width is consistent with the width of the compliant photovoltaic module 8, for detecting whether the width of the photovoltaic module 8 meets the standard.

[0050] The hole detection assembly 4 includes a second detection stage 41, a pin 42, a second spring 43, a second docking rod 44, and a second pressure sensor 45. The pin 42 is disposed on the second detection stage 41, and the distribution of the pin 42 relative to the second detection stage 41 satisfies the following condition: when a qualified photovoltaic module 8 is placed on the second detection stage 41, the pin 42 can penetrate the holes at the four corners of the qualified photovoltaic module 8; to detect whether the preset holes on the photovoltaic module 8 are in a through state. The second docking rod 44 is located directly above the second detection platform 41. The second spring 43 is sleeved on the second docking rod 44, and the second docking rod 44 is slidably connected to the docking ring 12 through the second spring 43, with the sliding direction parallel to the driving direction of the second cylinder 242. The second pressure sensor 45 is disposed on the docking ring 12 and located directly above the second docking rod 44. The adsorption member 25 can rotate between the second docking rod 44 and the second detection platform 41 as the movable ring 22 rotates. When both the second spring 43 and the relief spring 252 are deformed, the lower end of the second docking rod 44 is attached to the upper end of the connecting rod 251, and the top end of the second docking rod 44 is attached to the second pressure sensor 45. When the lifting member 24 moves the second docking rod 44 and the adsorption member 25 downward so that the photovoltaic module 8 is placed on the second detection platform 41, the second docking rod 44 is positioned directly above the second detection platform 41. During the testing process on the testing platform 41, if the preset hole on the photovoltaic module 8 is not fully penetrated or the opening position of the preset hole is not suitable for the pin 42 to pass through, the pin 42 will obstruct the downward movement of the photovoltaic module 8, thereby causing the photovoltaic module 8 to move upward, the connecting rod 251 to move upward due to the pressure of the photovoltaic module 8, and the second docking rod 44 to move upward due to the push of the connecting rod 251 and press against the second pressure sensor 45, so that the second pressure sensor 45 detects the pressure value. The controller 6 is used to receive the pressure value detected by the second pressure sensor 45, and when the pressure value is equal to the preset pressure value (i.e., the pushing force when the second docking rod 44 pushes against the second pressure sensor 45 upward), it controls the preset warning light to light up, so as to remind the testing personnel that the hole opened on the photovoltaic module 8 on the second testing platform 41 corresponding to the current warning light is not up to standard.

[0051] The visual appearance inspection component 5 specifically includes a third inspection platform 51 and a camera device 52. The camera device 52 is used to capture inspection images with the third inspection platform 51. The third inspection platform 51 is located directly below the rotation path of the movable ring 22 of the adsorption member 25. Therefore, when the photovoltaic module 8 is transported to the third inspection platform 51 by the combined action of the adsorption member 25, the lifting member 24, and the rotating member 23, the inspection image captured by the camera device 52 will contain the photovoltaic module 8. The adsorption member 25 can release the adsorption on the photovoltaic module 8, and the adsorption member 25 can be moved upward by the lifting member 24, so that the photovoltaic module 8 is placed on the third inspection platform 51, making it convenient for the inspection camera device 52 to capture the photovoltaic module 8 completely and clearly in the inspection image. The controller 6 is used to receive the inspection image with the photovoltaic module 8, compare the inspection image with the pre-stored image, and display the comparison result through the pre-connected display screen. The comparison result specifically includes the inspection image and the judgment result of whether the appearance meets the standard. If the comparison between the detected image and the pre-stored image is inconsistent, the result is deemed as substandard. The pre-stored image is the detected image obtained when the compliant photovoltaic module 8 is on the third detection station 51.

[0052] Reference Figure 1 , Figure 2 and Figure 3 It also includes a screening component 7, which includes a second conveyor belt 71 and a third conveyor belt 72. The first conveyor belt 71, the second conveyor belt 71 and the third conveyor belt 72 are arranged sequentially along the conveying direction of the photovoltaic module 8, and the ends of the second conveyor belt 71 and the third conveyor belt 72 are located directly below the rotation path of the adsorption member 25 when it rotates with the movable ring 22. The second conveyor belt 71 is used to receive and output substandard photovoltaic modules 8, and the third conveyor belt 72 is used to receive and output compliant photovoltaic modules 8.

[0053] The second conveyor belt 71 and the third conveyor belt 72 are provided with stacked receiving boxes at one end away from the frame 1. The receiving boxes are open and tilted upward at the end near the second conveyor belt 71 and the third conveyor belt 72. The opening of the bottom receiving box faces the end of the second conveyor belt 71 and the third conveyor belt 72 to receive the photovoltaic modules 8 conveyed by the second conveyor belt 71 and the third conveyor belt 72. When the bottom receiving box is full of photovoltaic modules 8, it can be removed so that the remaining empty receiving boxes move down under their own weight, so that the opening of the bottom empty receiving box faces the end of the second conveyor belt 71 and the third conveyor belt 72.

[0054] Accordingly, the controller 6 records the position of the adsorption component 25 that adsorbs the substandard photovoltaic module 8 and the estimated time required for it to move to the second conveyor belt 71 when a substandard detection result is obtained after any of the size detection component 3, hole type detection component 4, and visual appearance detection component 5. After the estimated time at the current moment, the controller 6 pauses the rotation of the moving ring 22 so that the adsorption component 25 moves precisely above the end of the second conveyor belt 71. Then, the controller controls the adsorption component 25 to move downwards and release its adsorption on the photovoltaic module 8, ultimately conveying the substandard photovoltaic module 8 onto the second conveyor belt 71. When determining the position of the adsorption component 25 that adsorbs the substandard photovoltaic module 8, this position is assumed to be the position of the first detection platform 31, the second detection platform 41, or the third detection platform 51, and the corresponding estimated time is the time it takes for the adsorption component 25 to move from above the first detection platform 31, the second detection platform 41, or the third detection platform 51 to the second conveyor belt 71. In other embodiments, each adsorption element 25 may be pre-labeled with a unique tag, and a scanning module (RFID tag scanner) may be provided above the second conveyor belt 71 to scan and read the tags of each adsorption element 25 above the second conveyor belt 71. When a substandard photovoltaic module 8 is detected, the tag of the adsorption element 25 that adsorbs the corresponding substandard photovoltaic module 8 is recorded. When the scanning module scans the corresponding tag, the rotation of the moving ring 22 is stopped, and the lifting element 24 and the adsorption element 25 release the corresponding substandard photovoltaic module 8 onto the second conveyor belt 71.

[0055] Example 2

[0056] The difference between Embodiment 2 and Embodiment 1 in this application is that: (Refer to...) Figure 3 , Figure 4 and Figure 5 The screening assembly 7 also includes pull ropes 73, limiting springs 74, and motors 75, each corresponding to an adsorption element 25. Each support rod 221 has a slider 222 slidably connected along its length. A connecting rod 251 passes through the corresponding slider 222, and one end of the relief spring 252 is connected to the connecting rod 251, while the other end is connected to the slider 222. The limiting spring 74 is sleeved on the corresponding support rod 221, with one end connected to the support rod 221 and the other end connected to the slider 222. One end of the pull rope 73 is connected to the corresponding slider 222, and the other end is connected to the drive shaft of the motor 75. When the limiting spring 74 is not deformed, the connecting rod 251 can rotate with the rotation of the movable ring 22 to above the end of the first conveyor belt 21, above the end of the second conveyor belt 71, and directly above the first detection table 31, the second detection table 41, and the third detection table 51.

[0057] Reference Figure 3 , Figure 4 and Figure 5Each of the first detection station 31, the second detection station 41, and the third detection station 51 corresponds to a second conveyor belt 71. The second conveyor belt 71 is located directly below the sliding path of the adsorption member 25 above the first detection station 31, the second detection station 41, and the third detection station 51 when it slides relative to the corresponding support rod 221 in the length direction. Therefore, when a substandard photovoltaic module 8 is detected, the controller 6 will determine the location of the photovoltaic module 8 (i.e., the first detection station 31, the second detection station 41, or the third detection station 51), then control the motor 75 corresponding to the adsorption member 25 that adsorbs the photovoltaic module 8 to start and move the adsorption member 25 above the corresponding second conveyor belt 71, and then control the adsorption member 25 to release its adsorption on the photovoltaic module 8, thereby removing the substandard photovoltaic module 8.

[0058] Reference Figure 3 , Figure 4 and Figure 5 The visual appearance inspection component 5 also includes several light sources 53 located around the third inspection station 51 and illuminating the third inspection station 51 from a preset angle. When the photovoltaic module 8 is located on the third inspection station 51, the photovoltaic module 8 will be illuminated by the light sources 53 and cast a shadow on the surface of the third inspection station 51. The inspection image captured by the corresponding camera device 52 includes the shadow. The inspection image specifically includes the light and shadow image corresponding to each light source 53 illuminating the photovoltaic module 8 on the third inspection station 51 individually.

[0059] Furthermore, all light sources 53 satisfy the following: for each light source 53 illuminating a qualified photovoltaic module 8 individually, there exists a light and shadow image with a shared shadow surface in other light and shadow images; the controller 6 also pre-stores associated light and shadow images and their corresponding reference shadow surfaces, as well as the corresponding light sources 53; wherein, associated light and shadow images refer to light and shadow images with reference shadow surfaces, and light and shadow images with reference shadow surfaces are light and shadow images with an associated relationship, and the reference shadow surface is the shared shadow surface between the light and shadow images corresponding to the qualified photovoltaic modules 8 that are pre-stored by the controller 6;

[0060] The controller 6 is used to acquire all light and shadow images and, based on the one-to-one correspondence between the light and shadow images and the light source 53, determine whether the light and shadow images with a relationship in the currently acquired light and shadow images have a common shadow surface. If there is no common shadow surface or the existing common shadow surface is inconsistent with the corresponding reference shadow surface, it is considered that the photovoltaic module 8 has shifted during the process of individually illuminating the photovoltaic module 8 with different light sources 53 and taking corresponding light and shadow images. At this time, the controller 6 is used to correct all light and shadow images to obtain corrected light and shadow images, and then compare each corrected light and shadow image with the preset reference image pre-stored in the controller 6. If the comparison is inconsistent, the comparison result is determined to be a defective product, that is, a substandard photovoltaic module 8. The preset reference image contains all light and shadow images corresponding to the compliant photovoltaic module 8.

[0061] The aforementioned correction method can be specifically as follows: The placement position of the compliant photovoltaic module 8 relative to the third detection stage 51 in all photovoltaic images corresponding to the compliant photovoltaic module 8 included in the default baseline preset image is taken as the baseline position. The controller 6 pre-stores the corresponding light and shadow images (hereinafter referred to as replacement images) when the compliant photovoltaic module 8 deviates from the baseline position under the illumination of each individual light source 53. Accordingly, during correction, for each light and shadow image (hereinafter referred to as the target light and shadow image), the degree of deviation of the photovoltaic module 8 (excluding the shadow surface) in the target light and shadow image relative to the baseline position is determined to find the corresponding replacement image from the pre-stored replacement images. This replacement image replaces the target light and shadow image, thus achieving correction.

[0062] Furthermore, the controller 6 is also used to determine whether the deformation degree of the photovoltaic module 8 corresponding to the light and shadow image is within the preset deformation tolerance range when it is determined that the light and shadow image is inconsistent with the preset reference image. This is based on the pre-stored different deformation types and the shadow surface (hereinafter referred to as shadow surface A) corresponding to the deformation degree of each deformation type. If not, the comparison result is determined to be a defective product; otherwise, it is a good product. Each deformation type corresponds to one part of the photovoltaic module 8, such as the end or side. The corresponding deformation type is end deformation, side deformation, etc. The deformation tolerance range includes one or more specified shadow surfaces A among all shadow surfaces A. If the shadow surface corresponding to the currently detected photovoltaic module 8 is consistent with any of the shadow surfaces A included in the deformation tolerance range, it is considered to be within the preset deformation tolerance range.

[0063] This application also discloses a method for inspecting the shape of a photovoltaic module's molded structure, comprising the following steps:

[0064] The photovoltaic module 8 to be tested is sequentially transported to the size detection component 3, the hole shape detection component 4, and the visual appearance detection component 5 using the transport component;

[0065] The size detection component 3 is used to detect whether the size of the photovoltaic module 8 meets the standard; the hole type detection component is used to detect the size of the holes opened on the photovoltaic module 8 and whether the holes are connected; the visual appearance detection component 5 is used to capture an image of the appearance of the photovoltaic module 8 and detect whether there are any defects.

[0066] The controller 6 acquires the detection results of the size detection component 3, the hole type detection component 4, and the visual appearance detection component 5, and controls the screening component 7 to screen the photovoltaic modules 8 that meet the standards and those that do not.

[0067] It should be noted that in this paper, relational terms such as first and second are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations.

[0068] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit the scope of protection of the application. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on these embodiments, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

Claims

1. A system for inspecting the shape of a photovoltaic module's molded structure, characterized in that, The system includes a frame (1), on which a conveying assembly (2) for conveying photovoltaic modules (8) is provided. The frame (1) is provided with a size detection assembly (3), a hole type detection assembly (4), and a visual appearance detection assembly (5) in sequence along the conveying direction of the photovoltaic modules (8). The size detection assembly (3) is used to detect whether the size of the photovoltaic modules (8) meets the standard. The hole type detection assembly (4) is used to determine whether the holes opened on the photovoltaic modules (8) meet the standard. The visual appearance detection assembly (5) is used to determine whether the appearance of the photovoltaic modules (8) meets the standard. The system also includes a controller (6) and a screening assembly (7). The controller (6) is used to control the screening assembly (7) to screen photovoltaic modules (8) that meet the standard and those that do not meet the standard based on the detection results of the size detection assembly (3), the hole type detection assembly (4), and the visual appearance detection assembly (5). The conveying assembly (2) includes a movable ring (22) rotatably connected to the frame (1), a rotating component (23) for driving the movable ring (22) to rotate, a plurality of adsorption components (25) distributed circumferentially along the movable ring (22), a lifting component (24) for driving the movable ring (22) to rise and fall, and a first conveyor belt (21) for supplying photovoltaic modules (8); the adsorption component (25) is used to adsorb photovoltaic modules (8), and the adsorption component (25) can rotate to above the end of the first conveyor belt (21) during the rotation of the movable ring (22), and adsorb the photovoltaic modules (8) at the end of the conveyor belt by the descent action of the lifting component (24); the size detection component (3), the hole type detection component (4) and the visual appearance detection component (5) are used to detect the photovoltaic modules (8) adsorbed by the adsorption component (25); The size detection component (3) and the screening component (7) are both controlled by the controller (6). The size detection component (3) includes a first detection platform (31), a first docking rod (32), a first spring (33), and a first pressure sensor (34). Each adsorption component (25) is connected to a corresponding relief spring (252), and is slidably connected to the movable ring (22) along the lifting direction of the lifting component (24) through the corresponding relief spring (252). The frame (1) is also provided with a docking ring (12). The lifting component (24) is used to drive the movable ring (22) and the docking ring (12) to rise and fall together. The first detection platform (31) is provided with a slot (311) for inserting qualified photovoltaic modules (8). The distance by which the lifting component (24) drives the adsorption component (25) to fall is satisfied so that the qualified photovoltaic modules (8) adsorbed by the adsorption component (25) move down and are inserted into the slot (311). The first docking rod (32) is slidably connected to the docking ring (12) by the first spring (33), and the sliding direction of the first docking rod (32) relative to the docking ring (12) is parallel to the lifting direction of the movable ring (22) and the docking ring (12). When the target adsorption component (25) moves to the top of the first detection stage (31), the first docking rod (32) is located above the target adsorption component (25), wherein the target adsorption component (25) is any adsorption component (25). When the first spring (33) and the relief spring (252) are not deformed, the distance between the lower end of the first docking rod (32) and the top of the target adsorption member (25) is not greater than the depth of the slot (311). The first pressure sensor (34) is located at the other end of the first docking rod (32) to detect the pressure of the first docking rod (32) against the first pressure sensor (34) when the first docking rod (32) moves upward relative to the docking ring (12). The controller (6) is used to obtain the detection result of the first pressure sensor (34) and, when the detection result is a defective product, controls the screening component (7) to discharge the photovoltaic module (8) adsorbed by the adsorption member (25) above the first detection table (31).

2. The photovoltaic module molding structure shape inspection system according to claim 1, characterized in that, The aperture detection component (4) is controlled by the controller (6). The aperture detection component (4) includes a second detection stage (41), a pin (42) set on the second detection stage (41), a second spring (43) set on the docking ring (12), a second docking rod (44), and a second pressure sensor (45) set at the end of the second docking rod (44). The lifting component (24) drives the adsorption component (25) to descend by a distance that satisfies the following conditions: the qualified photovoltaic module (8) adsorbed by the adsorption component (25) moves down and the pin (42) penetrates the preset hole of the qualified photovoltaic module (8). The second docking rod (44) is slidably connected to the docking ring (12) by the second spring (43), and the sliding direction of the second docking rod (44) relative to the docking ring (12) is parallel to the lifting direction of the movable ring (22) and the docking ring (12). When the target adsorption component (25) moves above the second detection stage (41), the second docking rod (44) is located above the target adsorption component (25). When the second spring (43) and the relief spring (252) are not deformed, the distance between the lower end of the second docking rod (44) and the top end of the target adsorption member (25) is not greater than the length of the pin (42). The second pressure sensor (45) is located at the other end of the second docking rod (44) to detect the pressure of the second docking rod (44) against the second pressure sensor (45) when the second docking rod (44) moves upward relative to the docking ring (12). The controller (6) is used to obtain the detection result of the second pressure sensor (45) and, when the detection result is a defective product, controls the screening component (7) to discharge the photovoltaic module (8) adsorbed by the adsorption member (25) above the second detection table (41).

3. The photovoltaic module molding structure shape inspection system according to claim 1, characterized in that, The visual appearance inspection component (5) includes a third inspection platform (51), a camera device (52), and several light sources (53); the camera device (52) is located around the third inspection platform (51) to capture an inspection image with an image of the upper surface of the third inspection platform (51); several light sources (53) are located around the third inspection platform (51) and illuminate the third inspection platform (51) from a preset angle, and when the photovoltaic module (8) is located on the third inspection platform (51), the photovoltaic module (8) will be illuminated by the light sources (53). The light source (53) projects a shadow onto the surface of the third inspection station (51), and the inspection image captured by the camera device (52) includes the shadow. The controller (6) is used to acquire the inspection image and compare it with a preset reference image. When the comparison result is a defective product, the controller controls the screening component (7) to discharge the photovoltaic module (8) on the third inspection station (51). The reference image includes the shadow of the qualified photovoltaic module (8) on the third inspection station (51) when it is illuminated by the light source (53).

4. The photovoltaic module molding structure shape inspection system according to claim 3, characterized in that, The detection images include the light and shadow images corresponding to the photovoltaic module (8) on the third detection station (51) when each light source (53) individually illuminates it. The controller (6) is used to acquire all the light and shadow images and, based on all the light and shadow images, verify whether the photovoltaic module (8) shifts during the process of being illuminated and photographed by different light sources (53). If it shifts, all the light and shadow images are corrected and then compared with the preset reference image. If the comparison is inconsistent, the comparison result is determined to be a defective product. The preset reference image includes the light and shadow images corresponding to the compliant photovoltaic module (8).

5. The photovoltaic module molding structure shape inspection system according to claim 4, characterized in that, All the light sources (53) satisfy the following: for each light source (53) when it individually illuminates a qualified photovoltaic module (8), there exists a light and shadow image with a shared shadow surface in other light and shadow images; the controller (6) also pre-stores associated light and shadow images and their corresponding reference shadow surfaces; the associated light and shadow images refer to light and shadow images with a reference shadow surface and an associated relationship, and the reference shadow surface is a shared shadow surface between the light and shadow images corresponding to the qualified photovoltaic modules (8) that are pre-stored by the controller (6); The controller (6) is used to verify whether there is a common shadow surface in the light and shadow images that are related after acquiring the light and shadow images. If there is no common shadow surface or the common shadow surface is inconsistent with the corresponding reference shadow surface, the offset of the photovoltaic module (8) is verified.

6. The photovoltaic module molding structure shape inspection system according to claim 5, characterized in that, The controller (6) is used to determine whether the degree of deformation of the photovoltaic module (8) corresponding to the light and shadow image is within the preset deformation tolerance range when it is determined that the light and shadow image is inconsistent with the preset reference image. If it is not, the comparison result is determined to be a defective product, otherwise it is a good product.

7. The photovoltaic module molding structure shape inspection system according to claim 1, characterized in that, The screening component (7) includes a pull rope (73), a limiting spring (74), and a motor (75) that are arranged one-to-one with the adsorption element (25); the adsorption element (25) is connected to the movable ring (22) by sliding radially along the movable ring (22) through the limiting spring (74); one end of the pull rope (73) is connected to the adsorption element (25), and the other end is connected to the drive end of the corresponding motor (75); the motor (75) is arranged on the movable ring (22), and the motor (75) is controlled by the controller (6); the size detection component (3), the hole type detection component (4), and the visual appearance detection component (5) are respectively associated with defective product recovery tracks, and the defective product recovery tracks are located below the radial sliding path of the corresponding adsorption element (25) along the relative movable ring (22).

8. A method for detecting the shape of a photovoltaic module's molded structure, applied to the photovoltaic module's shape detection system as described in claim 1, characterized in that, include: The photovoltaic module (8) to be tested is transported sequentially to the size detection component (3), the aperture detection component (4), and the visual appearance detection component (5) using the transport component; The size of the photovoltaic module (8) is checked by the size detection component (3) to see if it meets the standard; the size of the holes and whether they are through are checked by the hole type detection component (4); and the appearance image of the photovoltaic module (8) is captured by the visual appearance detection component (5) and the defects are detected. The controller (6) acquires the detection results of the size detection component (3), the hole type detection component (4) and the visual appearance detection component (5), and controls the screening component (7) to screen the photovoltaic modules (8) that meet the standards and do not meet the standards.

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