A photovoltaic module production line, production process and photovoltaic module

Abstract

The present invention discloses a photovoltaic module production line, production process and photovoltaic module, which includes a welding area and a pasting and laying area distributed in sequence along the X direction, a first glass feeding area is provided at the glass feeding end of the welding area, and a second glass feeding area is provided at the second glass feeding end of the pasting and laying area; the welding area outputs materials along the X direction; the first glass feeding area includes a first glass feeding machine, a printer and a first film laying machine arranged in sequence along the reverse direction of X; the pasting and laying area includes a tape sticking machine, a small long side strip placing machine, a short side strip placing machine, a second film laying machine, a backboard cutting and laying machine and a laminating machine arranged in sequence along the X direction; the second glass feeding area is connected to the laminating machine. The present invention can meet the production needs of various types of battery modules, has a scientific and reasonable layout, reduces the production line footprint, and reduces the production line cost.

Description

Technical Field

[0001] The present invention belongs to the technical field of photovoltaic module production lines, and particularly relates to a photovoltaic module production line, a production process, and a photovoltaic module. Background Art

[0002] The most core device of solar photovoltaic power generation is the solar cell. The principle of the solar cell is to directly convert solar radiation into electrical energy based on the photovoltaic effect of semiconductors. There are many types of solar cell modules, such as crystalline silicon solar modules (monocrystalline silicon modules, polycrystalline silicon modules, high-efficiency crystalline silicon modules such as PERC / TOPCon / HJT / BC, etc.), thin-film solar modules (amorphous silicon thin-film modules, cadmium telluride thin-film modules, copper indium gallium selenide thin-film modules, etc.), and emerging technologies (perovskite battery modules, organic photovoltaics, etc.). Currently, the mainstream technology is still crystalline silicon solar modules.

[0003] Due to the emergence of various photovoltaic modules, many current photovoltaic module manufacturers no longer only produce one type of photovoltaic module, but may be able to simultaneously meet the automated production of multiple different types of photovoltaic modules on one production line. Therefore, the flexibility and compatibility of the photovoltaic module production line become particularly important. In addition, due to the large number of assembly processes for photovoltaic modules, the overall length of the photovoltaic module production line is relatively long, and the floor area occupied by the production line is relatively large. Therefore, the optimized layout of the photovoltaic module production line is also particularly important. The layout of the front and back processes and the shape design of the line body will directly affect the production efficiency of the module, the number of workers, logistics, equipment costs, etc.

[0004] In the prior art, patent CN213124467U discloses a fully automatic production line for photovoltaic modules. Although it realizes the automatic assembly of photovoltaic modules, this production line has the following defects:

[0005] (1) The laying process only includes the back EVA loading area and the backplane loading area, which cannot meet the assembly requirements of currently popular TOPCon battery modules or BC battery modules, and has poor versatility;

[0006] (2) In the welding process, there are only three cell string welders, and the production capacity is relatively low, which cannot meet the production requirements of higher production capacity.

[0007] Therefore, it is necessary to provide a new photovoltaic module production line, production process, and photovoltaic module to solve the above technical problems. Summary of the Invention

[0008] One of the main purposes of the present invention is to provide a photovoltaic module production line that can meet the production requirements of various types of battery modules, has a scientific and reasonable layout, reduces the floor area of the production line, and reduces the production line cost.

[0009] The present invention realizes the above object through the following technical solutions: A photovoltaic module production line, which includes a welding area and a pasting and laying area arranged in sequence along the X direction. A first glass loading area is provided at the glass loading end of the welding area, and a second glass loading area is provided at the second glass loading end of the pasting and laying area; the welding area outputs materials along the X direction.

[0010] The first glass loading area sequentially includes along the reverse X direction:

[0011] A first glass loading machine for supplying the first-layer glass;

[0012] An inkjet printer for spraying information codes at specified positions on the first-layer glass;

[0013] A first-layer film laying machine for laying a first-layer film on the first-layer glass;

[0014] The pasting and laying area sequentially includes along the X direction:

[0015] A tape pasting machine for pasting and fixing the battery string on the first-layer glass;

[0016] A small long-edge tape placing machine for placing two long-edge tapes on the long sides of the first-layer glass and placing a tape block at the lead wire;

[0017] A short-edge tape placing machine for placing two short-edge tapes on the short sides of the first-layer glass;

[0018] A second-layer film laying machine for laying a second-layer film above the battery string;

[0019] A backsheet cutting and laying machine for laying a backsheet above the second-layer film;

[0020] A laminator, which is docked with the second glass loading area. The laminator covers the second-layer glass on the first-layer glass to achieve double-glass lamination.

[0021] Furthermore, the welding area includes a first conveyor line body for conveying materials along the X direction, several battery string welders arranged along the X direction on the side opposite to the reverse Y direction of the first conveyor line body and outputting battery strings along the Y direction, several layout machines arranged on the output side of the battery string welders and located between the battery string welders and the first conveyor line body, a second conveyor line body that connects all the layout machines in parallel along the X direction and conveys materials along the reverse X direction, and a battery string end welder arranged at the end section of the first conveyor line body; the pasting and laying area is arranged along the extension line of the first conveyor line body.

[0022] Further, the first conveyor line body and the second conveyor line body are parallelly distributed and convey materials in the X direction, wherein the first conveyor line body conveys materials in the X direction, and the second conveyor line body conveys materials in the opposite direction of X; the first conveyor line body conveys a glass plate with a battery string arranged thereon to the subsequent battery string end welder; the second conveyor line body conveys a glass plate to each of the typesetting machines; the first glass loading area is arranged at the conveying head end of the second conveyor line body for docking.

[0023] Further, the battery string welder and the first conveyor line body are respectively located on both sides of the second conveyor line body in the Y direction; one typesetting machine is correspondingly configured for the output sides of every two battery string welders, and two typesetting robots are configured in each typesetting machine for simultaneous typesetting.

[0024] Further, a total of eight battery string welders and four typesetting machines are arranged in the welding area.

[0025] Further, a commutation mechanism is arranged at the position on the first conveyor line body for docking with the typesetting machine. The typesetting machine outputs a glass plate with a battery string arranged thereon along the long side in the Y direction onto the first conveyor line body, and then horizontally commutes through the commutation mechanism, outputs a glass plate along the long side in the X direction into the battery string end welder, and then inputs it into the pasting and laying area for subsequent processes.

[0026] Further, a first commutation conveyor mechanism is arranged at the output end of the single-layer adhesive film laying machine, and a second commutation conveyor mechanism is arranged at the input end of the second conveyor line body;

[0027] The single-layer adhesive film laying machine outputs a glass plate with a single-layer adhesive film laid thereon along the long side in the opposite direction of X. After being horizontally commuted and adjusted by the first commutation conveyor mechanism, it outputs a glass plate with a single-layer adhesive film laid thereon along the short side in the Y direction; the second commutation conveyor mechanism receives a glass plate input along the short side in the Y direction, horizontally commutes and adjusts it, and then outputs a glass plate along the long side in the opposite direction of X onto the second conveyor line body.

[0028] Further, the small long-edge rubber strip placer includes a component conveyor line, a long-strip cutting and feeding module, a long-strip handling and placing module, a small-piece cutting and feeding module, and a small-piece handling and placing module arranged above the component conveyor line.

[0029] Further, the pasting and laying area further includes a lead bending and high-temperature cloth placing machine, a pre-EL detector, and an edge sealing machine arranged in sequence along the X direction; the lead bending and high-temperature cloth placing machine places a high-temperature cloth at the lead and bends and flattens the lead; the pre-EL detector includes several layers of detection stations; the edge sealing machine includes several layers of edge sealing stations. A first lifting and stacking line body is configured at the input side of the pre-EL detector, and a second lifting and stacking line body is configured at the output side of the edge sealing machine.

[0030] Further, a third lifting stacking line body is arranged between the small-piece long-edge rubber strip placing machine and the short-edge rubber strip placing machine; a fourth lifting stacking line body is arranged between the backboard cutting and laying machine and the laminating machine.

[0031] Further, the conveying line body at the front EL inspection machine is a reversing conveying line with a reversing conveying function; a sixth lifting stacking line body is arranged on the X negative direction side of the front EL inspection machine; the pasting and laying area is further equipped with an AGV connecting trolley. When the cache quantity of the sixth lifting stacking line body reaches the set value, the defective products are taken out by the AGV connecting trolley and transported to the repair area for centralized repair processing. After the repair is qualified, they are sent back to the sixth lifting stacking line body by the AGV connecting trolley and then returned to the front EL inspection machine through the sixth lifting stacking line body.

[0032] Further, the second glass loading area includes a second glass loading machine and a third reversing conveying line. The second glass loading machine outputs two-way glass along the long side in the X direction and outputs two-way glass along the short side in the Y direction after being reversed by the third reversing conveying line; a fifth lifting stacking line body is arranged on the Y direction output side of the third reversing conveying line.

[0033] Further, the second glass loading area includes a second glass loading machine and a gap film pasting device arranged on the output side of the second glass loading machine; the gap film pasting device includes a long-edge gap film feeding and pasting unit, a short-edge gap film feeding and pasting unit, a first handling mechanism and a second handling mechanism.

[0034] Further, the second glass loading machine outputs two-way glass along the long side in the X direction to the two-way glass loading station. The long-edge gap film feeding and pasting unit is arranged on the X direction output side of the two-way glass loading station. The first handling mechanism transports the two-way glass from the two-way glass loading station along the X direction to the long-edge gap film feeding and pasting unit for automatic pasting of the long-edge side gap film; the short-edge gap film feeding and pasting unit is arranged on the Y direction side of the long-edge gap film feeding and pasting unit and close to the laminating machine. The second handling mechanism horizontally reverses and transports the two-way glass from the long-edge gap film feeding and pasting unit to the short-edge gap film feeding and pasting unit; the laminating manipulator in the laminating machine sucks the two-way glass with the gap film pasted on the lower surface from the short-edge gap film feeding and pasting unit and covers it on the one-way glass to complete the lamination.

[0035] Another object of the present invention is to provide a photovoltaic module production process implemented based on the photovoltaic module production line as described above, including the following steps:

[0036] S1. In the first glass loading area, one-step glass loading, inkjet coding, and laying of a layer of adhesive film are completed: A first glass loading machine loads one piece of glass onto the production line. An inkjet coder sprays information codes at designated positions on the one-piece glass. A one-step adhesive film laying machine lays an adhesive film on the one-piece glass.

[0037] S2. The first glass loading area outputs the one-piece glass along the short side in the Y direction. After horizontal reversal by a reversing conveying mechanism, it is conveyed along the long side in the reverse X direction into the second conveying line body and enters the welding area.

[0038] S3. In the welding area, a battery string welder outputs battery strings along the Y direction. The one-piece glass is conveyed by the second conveying line body to a typesetting machine. The typesetting machine arranges the battery strings on the one-piece glass in a set manner. The typeset one-piece glass is output along the long side in the Y direction onto the first conveying line body, and then conveyed along the X direction to a battery string end welder to weld the bus bars, connecting all the battery strings together, and continuing to be conveyed along the long side in the X direction into the pasting and laying area.

[0039] S4. In the pasting and laying area, according to the process requirements of different types of photovoltaic modules, multiple or all of the processes of tape pasting, long-side strip placement, small-piece placement, short-side strip placement, two-step adhesive film laying, backplane laying, laminating, high-temperature cloth placement, lead wire bending, EL detection, and edge sealing are completed in sequence.

[0040] S5. The photovoltaic modules output from the pasting and laying area are further split and enter multiple laminators for lamination operations.

[0041] Further, in step S4, if a laminating operation is included, at the laminating operation station, the second glass loading area completes the loading of the two-piece glass.

[0042] Further, if it is necessary to paste a gap reflective film on the lower surface of the two-piece glass, the automatic pasting of the long-side gap film and the short-side gap film is completed by a gap film pasting device.

[0043] Another object of the present invention is to provide a photovoltaic module produced by using the above-mentioned photovoltaic module production line or by using the above-mentioned photovoltaic module production process.

[0044] Compared with the prior art, the beneficial effects of a photovoltaic module production line, production process, and photovoltaic module of the present invention are as follows: It can meet the production requirements of various types of battery modules, has a scientific and reasonable layout, reduces the floor area of the production line, and lowers the production line cost. Specifically:

[0045] (1) In the welding area, all the cell string welding machines are arranged and distributed along the X direction. Each single cell string welding machine extends along the Y direction and outputs cell strings along the Y direction. A layout machine is set on the output side of the cell string welding machines. All the layout machines are connected in parallel by the second conveyor line body, which serves as the loading conveyor line for the first piece of glass in the welding area. After the first piece of glass is conveyed to the position of the layout machine, high-efficiency layout is carried out by double robots, and then it is output along the Y direction onto the first conveyor line body. All the first pieces of glass with the cell strings laid out are output to the right along the X direction from the first conveyor line body and conveyed to the end welding machine at the end section of the first conveyor line body for end welding operation. The overall layout is reasonable, with a small floor area. Eight cell string welding machines are arranged side by side, greatly improving the production capacity.

[0046] (2) The first glass loading area is set at the head end of the second conveyor line body, overlapping with the subsequent pasting and laying area in the X direction. Therefore, it will not increase the length of the entire production line. A coding machine is set in the first glass loading area. The coding machine is used to directly spray information codes on the first piece of glass. On the one hand, it improves the security of the information codes on the first piece of glass and ensures the reliability of subsequent information reading of the information codes. On the other hand, it eliminates the subsequent printing of information barcodes and the information code pasting mechanism.

[0047] (3) A small long-edge tape placing machine, a short-edge tape placing machine, a laminating machine, and a lead bending and high-temperature cloth placing machine are set in the pasting and laying area, meeting the production process requirements of Topcon battery modules. At the same time, the entire production line can also meet the process requirements of conventional battery modules.

[0048] (4) A gap film pasting device is set in the second glass loading area, meeting the production process requirements of Topcon battery modules while also meeting the production process requirements of BC battery modules, improving the flexibility and versatility of the production line and being able to meet the production requirements of various different types of battery modules.

[0049] (5) All the equipment in the pasting and laying area is arranged and distributed in sequence along the extension line of the first conveyor line body in the welding area. A blank area is reserved in the X direction area between the cell string welding machines and the layout machine and on the Y direction side of the pasting and laying area. This blank area is exactly used to layout the first glass loading area and the second glass loading area, without additionally occupying the area for the length and width expansion of the entire production line. The layout is scientific and reasonable, and the logistics flow of the overall production line is not too circuitous. Compared with the original production line at the customer's site, 35 sets of production lines are saved, reducing the cost of the production line, and the length of the entire line in the X direction is also shortened by the length of one laminator, reducing the floor area. Brief Description of the Drawings

[0050] Figure 1 It is a top view schematic diagram of an embodiment of the present invention;

[0051] Figure 2 It is a top view of the welding area in the embodiment of the present invention;

[0052] Figure 3 It is a top view of the first glass loading area in the embodiment of the present invention;

[0053] Figure 4 It is a top view schematic diagram of the small-piece long-edge rubber strip placer in the embodiment of the present invention;

[0054] Figure 5 It is a top view of the second glass loading area in the embodiment of the present invention;

[0055] Figure 6 It is another top view schematic diagram of the second glass loading area in the embodiment of the present invention;

[0056] Figure 7 It is a top view schematic diagram of the lamination area in the embodiment of the present invention;

[0057] The numbers in the figure represent:

[0058] 100 - Photovoltaic module production line;

[0059] 10 - Welding area, 11 - First conveyor line body, 111 - Reversing mechanism, 12 - Cell string welder, 13 - Layout machine, 14 - Second conveyor line body, 15 - Cell string end welder;

[0060] 20 - Paste and lay area, 21 - Tape applicator, 22 - Small-piece long-edge rubber strip placer, 221 - Component conveyor line, 222 - Long-strip cutting and feeding module, 223 - Long-strip handling and placing module, 224 - Small-piece cutting and feeding module, 225 - Small-piece handling and placing module, 23 - Short-edge rubber strip placer, 24 - Second adhesive film laying machine, 25 - Backsheet cutting and laying machine, 26 - Laminating machine, 27 - Lead bending and high-temperature cloth placing machine, 28 - Front EL detector, 29 - Edge sealing machine, 210 - First lifting and stacking line body, 211 - Second lifting and stacking line body, 212 - Third lifting and stacking line body, 213 - Fourth lifting and stacking line body, 214 - Sixth lifting and stacking line body, 215 - AGV connection cart;

[0061] 30 - Lamination area, 31 - Laminator, 32 - Third conveyor line body, 33 - Seventh lifting and stacking line body;

[0062] 40 - First glass loading area, 41 - First glass loader, 42 - Inkjet printer, 43 - First adhesive film laying machine, 44 - First reversing conveyor mechanism, 45 - Second reversing conveyor mechanism, 46 - Buffer mechanism;

[0063] 50 - Second glass loading area, 51 - Second glass loader, 52 - Third reversing conveyor line, 53 - Fifth lifting stack line body, 54 - Gap film pasting device, 541 - Long side gap film feeding and pasting unit, 542 - Short side gap film feeding and pasting unit, 543 - First handling mechanism, 544 - Second handling mechanism, 55 - Second glass loading station. Detailed implementation mode

[0064] Example 1:

[0065] Please refer to Figures 1-7 , this embodiment is a photovoltaic module production line 100, which includes a welding area 10, a pasting and laying area 20, and a lamination area 30 distributed in sequence along the X direction. A first glass loading area 40 is provided at the glass loading end of the welding area 10, and a second glass loading area 50 is provided at the second glass loading end of the pasting and laying area 20.

[0066] The welding area 10 includes a first conveyor line body 11 for conveying materials along the X direction, a number of cell string welders 12 arranged along the X direction on the Y - reverse side of the first conveyor line body 11 and outputting cell strings along the Y direction, a number of typesetting machines 13 provided on the output side of the cell string welders 12 and located between the cell string welders 12 and the first conveyor line body 11, a second conveyor line body 14 that connects all the typesetting machines 13 in parallel along the X direction and conveys materials along the X - reverse direction, and a cell string end welder 15 provided at the tail section of the first conveyor line body 11.

[0067] The first conveyor line body 11 and the second conveyor line body 14 are parallelly distributed and convey materials along the X direction. Among them, the first conveyor line body 11 conveys materials along the positive X direction, and the second conveyor line body 14 conveys materials along the X - reverse direction. The pasting and laying area 20 is provided at the conveying end of the first conveyor line body 11, and the first glass loading area 40 is provided at the conveying head of the second conveyor line body 14. The first conveyor line body 11 conveys the first - pass glass plates typeset with cell strings to the subsequent cell string end welder 15; the second conveyor line body 14 conveys the first - pass glass to each typesetting machine 13.

[0068] A number of cell string welders 12 are arranged along the X direction. A single cell string welder 12 extends along the Y direction. The cell string welders 12 and the first conveyor line body 11 are located on both sides of the second conveyor line body 14 in the Y direction. In order to improve the production rhythm and the production capacity of the production line, in this embodiment, one typesetting machine 13 is correspondingly configured for the output sides of every two cell string welders 12, and two typesetting robots are configured in each typesetting machine 13 for simultaneous typesetting to improve the production rhythm. In this embodiment, a total of eight cell string welders 12 and four typesetting machines 13 are provided, and the production rhythm can reach 12s.

[0069] The battery cell string welder 12 and the layout machine 13 can both adopt the structures in the prior art. For example, the layout machine 13 can adopt the double-robot high-efficiency layout machine disclosed in the patent CN202420500477.5 in the prior art, or a photovoltaic module battery string high-speed layout device disclosed in the patent CN202421168911.0, or a multi-to-multi string welding layout continuous production line disclosed in the patent CN202311009347.8, etc.

[0070] A reversing mechanism 111 is provided at the position where the layout machine 13 is docked on the first conveyor line body 11. The layout machine 13 outputs a piece of glass with battery strings arranged in the long side direction along the Y direction onto the first conveyor line body 11, then adjusts the direction of the piece of glass through the reversing mechanism 111, and then outputs a piece of glass in the long side direction along the X direction into the battery string end welder 15, and then inputs it into the pasting and laying area 20 for subsequent processes.

[0071] The first glass loading area 40 includes a first glass loader 41, an inkjet printer 42, and a single-layer EVA film laying machine 43 arranged in sequence along the reverse X direction.

[0072] The first glass loader 41 is used to realize the automatic loading of a piece of glass and can adopt the structure in the prior art. For example, a photovoltaic module glass loading device disclosed in the patent CN202420171430.9.

[0073] The inkjet printer 42 is used to spray information codes at specified positions on the loaded piece of glass.

[0074] The single-layer EVA film laying machine 43 is used to lay a layer of EVA film on a piece of glass.

[0075] In this embodiment, an inkjet printer 42 is provided between the first glass loader 41 and the single-layer EVA film laying machine 43, and an information code is sprayed when the piece of glass enters the line body. Compared with adding a barcode pasting mechanism or device on the lower surface of the glass plate at a specified workstation in the original pasting and laying area 20, on the one hand, the subsequent addition of the barcode pasting mechanism or device on the lower surface of the glass plate is omitted. On the other hand, when the information code is pasted on the glass plate by the pasting method, there is a risk of the information code falling off during the process of the glass plate flowing through subsequent workstations along the production line, resulting in the inability to obtain the information code to generate an associated barcode in the future. However, there is no such risk problem when the information code is obtained by the spraying method.

[0076] To meet the high - efficiency cycle, in this embodiment, the first glass loading machine 41 uses double - station loading. The two loading stations are arranged along the Y - direction. Therefore, the overall length dimension of the first glass loading machine 41 along the Y - direction is relatively large, making it impossible to set the output side of the first glass loading machine 41 on the extension line of the second conveyor line 14. Furthermore, the output side of the first glass loading machine 41 can only be offset in the opposite direction of Y. Therefore, to achieve the docking between the first glass loading area 40 and the welding area 10, in this embodiment, a first reversing conveyor mechanism 44 is provided at the output end of the single - layer film laying machine 43, and a second reversing conveyor mechanism 45 is provided at the input end of the second conveyor line 14. The docking between the first glass loading area 40 and the welding area 10 is achieved through the second reversing conveyor mechanism 45.

[0077] Specifically, the single - layer film laying machine 43 outputs a single - layer glass with a single - layer film laid along the long side in the opposite direction of X, and then the first reversing conveyor mechanism 44 outputs a single - layer glass with a single - layer film laid along the short side in the Y - direction, realizing the output of a single - layer glass loading in the first glass loading area 40.

[0078] The first glass loading area 40 outputs a single - layer glass with a single - layer film laid along the short side in the Y - direction. The second reversing conveyor mechanism 45 receives the single - layer glass input along the short side in the Y - direction, and then outputs a single - layer glass along the long side in the opposite direction of X onto the second conveyor line 14.

[0079] To adjust the cycle between the first glass loading area 40 and the welding area 10, so that the production of each station can run smoothly and avoid jams and downtime waiting. The first reversing conveyor mechanism 44 in this embodiment is a steering lifting buffer mechanism with lifting and buffering functions. In other embodiments, a first reversing conveyor mechanism 44 can also be set at the output side of the single - layer film laying machine 43, and then a buffer mechanism 46 is connected in series at the output side of the first reversing conveyor mechanism 44, and the output side of the buffer mechanism 46 is then connected to the second reversing conveyor mechanism 45.

[0080] To meet the assembly requirements of various types of photovoltaic modules, this embodiment optimizes the design of the pasting and laying area 20. Specifically, the pasting and laying area 20 includes a tape - sticking machine 21, a small - piece long - side tape - placing machine 22, a short - side tape - placing machine 23, a double - layer film laying machine 24, a back - plate cutting and laying machine 25, a laminator 26, a lead - bending and high - temperature cloth - placing machine 27, a front EL detector 28, and an edge - sealing machine 29, which are arranged in sequence along the extension line of the first conveyor line 11. The second glass loading area 50 is connected to the laminator 26.

[0081] A glass carrier EVA film and several battery strings in a layout are input into the pasting and laying area 20 along the long side in the X direction. The tape pasting at the specified position is completed by the tape pasting machine 21, which is mainly used to fixedly bond adjacent battery strings together; through the small long-side strip placing machine 22, two long-side EVA strips are placed at the specified position on the long side, and EVA small pieces are placed at three lead positions; through the short-side strip placing machine 23, two short-side EVA strips are placed at the specified position on the short side; the cutting and laying of the second EVA film is completed by the second film laying machine 24; the cutting and laying of the backplane TPT is completed by the backplane cutting and laying machine 25; the laminating operation of the second glass and the first glass is completed by the laminating machine 26 sucking the second glass output from the second glass feeding area 50; through the lead bending and high-temperature cloth placing machine 27, high-temperature cloth is sleeved at three lead positions, and then the leads are bent and flattened for subsequent lamination operations; the EL detection is completed by the front EL detector 28; the edge sealing is completed around the glass by the edge sealing machine 29, and finally it enters the lamination area 30.

[0082] The tape pasting machine 21 can adopt the structure in the prior art, such as the battery string assembly automatic tape pasting device disclosed in the patent CN214692516U, or the efficient tape pasting device for fixing the battery strings of a photovoltaic module disclosed in CN221420191U.

[0083] The small long-side strip placing machine 22 includes a component conveying line 221, a long strip cutting and feeding module 222, a long strip handling and placing module 223, a small piece cutting and feeding module 224, and a small piece handling and placing module 225 arranged above the component conveying line 221. The long strip cutting and feeding module 222 and the long strip handling and placing module 223 can refer to the film cutting and placing machine for photovoltaic module processing disclosed in CN221026771U. The small piece cutting and feeding module 224 and the small piece handling and placing module 225 can adopt the structure in the prior art, such as the partial structure of the insulating small piece punching, cutting, placing and multi-functional labeling integrated device disclosed in the patent CN222396010U, or the insulating sheet cutting and paving integrated device disclosed in CN219726520U, or the full-automatic insulating sheet placing machine for photovoltaic modules disclosed in CN215911436U, etc.

[0084] The short-side strip placing machine 23 has basically the same structure as the long-side strip placing module 221, and the difference is that the short-side strip placing machine 23 realizes the cutting and placing of the short-side EVA long strips.

[0085] The lead bending and high-temperature cloth placing machine 27 can adopt the structure in the prior art, such as a photovoltaic module lead insulation rubber block placement and hot-pressing equipment disclosed in patent CN222396004U, or an insulation sheet cutting and laying integrated equipment disclosed in CN219726520U, or an insulation sheet fully automatic placement machine for photovoltaic modules disclosed in CN215911436U.

[0086] The placement of EVA blocks is similar to that of high-temperature cloth. Both require shaping and straightening of the leads to facilitate the placement of the EVA blocks or high-temperature cloth. The difference is that after the high-temperature cloth is placed in place, the leads need to be bent and flattened, while the EVA blocks do not need to be bent and flattened after they are placed in place.

[0087] In order to adjust the production rhythm, the front EL inspection machine 28 and the edge banding machine 29 can both adopt a multi-layer structure design, that is, the front EL inspection machine 28 has several layers of inspection stations distributed up and down, and the edge banding machine 29 has several layers of edge banding stations distributed up and down and corresponding to the height of the inspection stations. A first lifting stacking line 210 is configured on the input side of the front EL inspection machine 28, and a second lifting stacking line 211 is configured on the output side of the edge banding machine 29. Through the design of the multi-layer structure, EL inspection and edge banding operations of multiple photovoltaic modules can be performed simultaneously, thereby improving production efficiency and meeting the 12s rhythm requirement.

[0088] In order to ensure that each work station in the pasting and laying area 20 can proceed smoothly and avoid material blockage and shutdown, a third lifting and stacking line 212 is arranged between the small long-edge adhesive strip placement machine 22 and the short-edge adhesive strip placement machine 23; a fourth lifting and stacking line 213 is arranged between the backboard cutting and laying machine 25 and the assembly machine 26.

[0089] If defective products appear at the front EL inspection machine 28, they need to be transferred to the manual rework area for rework. To achieve this function, the present embodiment sets the conveyor line at the front EL inspection machine 28 as a reversing conveyor line with a reversing conveying function, and sets a sixth lifting stack line 214 on the X-opposite side of the front EL inspection machine 28, and caches defective components through the sixth lifting stack line 214. The present embodiment also sets an AGV docking trolley 215. When the cache quantity of the sixth lifting stack line 214 reaches a set value, the defective products are taken out by the AGV docking trolley 215 and transported to the rework area for centralized rework.

[0090] In this embodiment, the second glass loading area 50 includes a second glass loader 51 and a third reversing conveyor line 52. The second glass loader 51 outputs the second-layer glass along the long side in the X direction, and after being reversed by the third reversing conveyor 52, outputs the second-layer glass along the short side in the Y direction. A fifth lifting stacker line body 53 is arranged on the output side of the third reversing conveyor line 52 in the Y direction, and provides the second-layer glass for the laminator 26 through the fifth lifting stacker line body 53.

[0091] In another embodiment, in order to meet the production requirements of BC battery modules, the second glass loading area 50 includes a second glass loader 51 and a gap film pasting device 54 arranged on the output side of the second glass loader 51. The gap film pasting device 54 includes a long-side gap film feeding and pasting unit 541, a short-side gap film feeding and pasting unit 542, a first handling mechanism 543 and a second handling mechanism 544. The gap film pasting device 54 can adopt the structure in the prior art. For example, a full-automatic pasting and laminating device and method for battery cell gap reflective film disclosed in Patent CN119029093B. In order to save space, the layout of the gap film pasting device 54 is as follows:

[0092] The second glass loader 51 outputs the second-layer glass along the long side in the X direction to the second-layer glass loading station 55. The long-side gap film feeding and pasting unit 541 is arranged on the output side of the second-layer glass loading station 55 in the X direction. The first handling mechanism 543 transports the second-layer glass from the second-layer glass loading station 55 along the X direction to the long-side gap film feeding and pasting unit 541 for automatic pasting of the long-side gap film; the short-side gap film feeding and pasting unit 542 is arranged on one side of the long-side gap film feeding and pasting unit 541 in the Y direction and close to the laminator 26. The second handling mechanism 544 transports the second-layer glass from the long-side gap film feeding and pasting unit 541 after a 90-degree horizontal reversal to the short-side gap film feeding and pasting unit 542; the laminating manipulator in the laminator 26 sucks the second-layer glass with the gap film pasted on the lower surface from the short-side gap film feeding and pasting unit 542 and covers it on the first-layer glass to complete laminating.

[0093] In this embodiment, the first glass loading area 40 and the second glass loading area 50 are located on the same side in the Y direction of the pasting and laying area 20 on the first conveyor line body 11 and its extension line, and on the opposite side in the reverse Y direction. The first glass loading area 40 and the second glass loading area 50 are automatically fed with glass stack materials through an AGV cart. The loading sides of the first glass loading area 40 and the second glass loading area 50 are arranged opposite to each other, forming a centralized glass loading area, which is beneficial to the neat and orderly layout of the on-site production line.

[0094] The laminating area 30 includes a plurality of laminators 31 arranged in a row along the Y direction and a third conveyor line 32 connecting the laminators 31 in parallel. The second lifting stacking line 211 on the output side of the edge banding machine 29 has a 90-degree horizontal reversing function. The first laminator 31 is docked and arranged on the output side of the second lifting stacking line 211 in the X direction. The third conveyor line 32 is provided with a seventh lifting stacking line 33 corresponding to other laminators 31. The seventh lifting stacking line 33 has a 90-degree horizontal reversing function. The edge banding machine 29 outputs photovoltaic modules along the long side in the X direction. The photovoltaic modules are divided into two paths through the second lifting stacking line 211. One path continues to enter the laminator 31 behind along the X direction. The other path outputs the photovoltaic modules along the short side in the opposite direction of the Y direction after 90-degree horizontal reversal to the subsequent seventh lifting stacking line 33. Then, the photovoltaic modules are output along the long side in the X direction to the corresponding laminator 31 after 90-degree horizontal reversal through the seventh lifting stacking line 33.

[0095] This embodiment also provides a production process based on the photovoltaic module production line, which includes the following steps:

[0096] S1, the first glass loading area 40 realizes loading, coding and laying of a layer of glass: the first glass loading machine 41 loads a layer of glass to the production line, the coding machine 42 sprays the information code at the specified position of the layer of glass, and the layer of film laying machine 43 lays the EVA film on the layer of glass;

[0097] S2, the first glass loading area 40 outputs a glass along the short side in the Y direction, and after being horizontally reversed by 90 degrees by the second reversing conveying mechanism 45, it is conveyed to the second conveying line body 14 along the long side in the opposite direction of X, and enters the welding area 10;

[0098] S3, in the welding area 10, the battery cell string welding machine 12 outputs the battery string along the Y direction, and a glass is transported to the typesetting machine 13 through the second conveyor line 14. The typesetting machine 13 arranges the battery string on a glass in a set manner. The typesetting glass is output to the first conveyor line 11 along the long side in the Y direction, and then transported to the battery string end welding machine 15 along the X direction to weld the busbars, connect all the battery strings together, and continue to transport the long side along the X direction to the pasting and laying area 20;

[0099] S4. In the pasting and laying area 20, according to the process requirements of different types of photovoltaic modules, the following processes are completed in sequence: tape pasting, long-side strip placement, small block placement, short-side strip placement, second-layer adhesive film laying, backboard laying, lamination, high-temperature cloth placement, lead bending, EL testing, and edge sealing;

[0100] S5. The photovoltaic modules output from the pasting and laying area 20 are then divided and sent to a plurality of laminators for lamination operation.

[0101] In step S4, if there is a laminating operation, at the laminating operation station, the feeding of the second glass is completed through the second glass feeding area 50. If it is necessary to paste the gap reflective film on the lower surface of the second glass, the automatic pasting of the long-side gap film and the short-side gap film is completed through the gap film pasting device 54.

[0102] In this embodiment, the "X direction" refers to the direction indicated by the X arrow in the accompanying drawings of the specification; the "opposite X direction" refers to the opposite direction of the direction indicated by the X arrow in the accompanying drawings of the specification. The "Y direction" refers to the direction indicated by the Y arrow in the accompanying drawings of the specification; the "opposite Y direction" refers to the opposite direction of the direction indicated by the Y arrow in the accompanying drawings of the specification. The "X-oriented" refers to the direction parallel to the direction indicated by the X arrow in the accompanying drawings of the specification, without distinction between positive and negative; the "Y-oriented" refers to the direction parallel to the direction indicated by the Y arrow in the accompanying drawings of the specification, without distinction between positive and negative. The included angle range between the "X direction" and the "Y direction" can be flexibly designed according to the actual site, for example, 20 degrees to 150 degrees, preferably 90 degrees.

[0103] For those of ordinary skill in the art, without departing from the inventive concept of the present invention, several modifications and improvements can still be made, and these all belong to the protection scope of the present invention.

Claims

1. A photovoltaic module production line, characterized in that: It includes a welding area and a pasting and laying area distributed in sequence along the X direction. At the glass loading end of the welding area, there is a first glass loading area, and at the second glass loading end of the pasting and laying area, there is a second glass loading area; the welding area outputs materials along the X direction; The first glass loading area sequentially includes along the reverse X direction: A first glass loading machine for supplying the first-layer glass; An inkjet printer for spraying information codes at designated positions on the first-layer glass; A first-layer adhesive film laying machine for laying a first-layer adhesive film on the first-layer glass; The pasting and laying area sequentially includes along the X direction: A tape pasting machine for pasting and fixing the battery string on the first-layer glass; A small long-edge rubber strip placing machine for placing two long-edge rubber strips on the long side of the first-layer glass and placing a rubber block at the lead wire; A short-edge rubber strip placing machine for placing two short-edge rubber strips on the short side of the first-layer glass; A second-layer adhesive film laying machine for laying a second-layer adhesive film above the battery string; A backplane cutting and laying machine for laying a backplane above the second-layer adhesive film; A laminator, which is docked with the second glass loading area. The laminator covers the second-layer glass on the first-layer glass to achieve double-glass lamination.

2. The photovoltaic module production line according to claim 1, characterized in that: The welding area includes a first conveyor line body for conveying materials along the X direction, several battery string welders arranged in sequence along the X direction on the side opposite to the reverse Y direction of the first conveyor line body and outputting battery strings along the Y direction, several layout machines arranged on the output side of the battery string welders and located between the battery string welders and the first conveyor line body, a second conveyor line body that connects all the layout machines in parallel along the X direction and conveys materials along the reverse X direction, and a battery string end welder arranged at the tail section of the first conveyor line body; the pasting and laying area is arranged along the extension line of the first conveyor line body.

3. The photovoltaic module production line according to claim 2, wherein: The first conveyor line body and the second conveyor line body are parallelly distributed and both convey materials along the X direction. Among them, the first conveyor line body conveys materials along the X direction, and the second conveyor line body conveys materials along the reverse X direction; the first conveyor line body conveys the first-layer glass plate with the battery string laid out to the subsequent battery string end welder; the second conveyor line body conveys the first-layer glass to each of the layout machines; the first glass loading area is arranged at the conveying head end of the second conveyor line body for docking.

4. The photovoltaic module production line according to claim 2, wherein: The battery string welders and the first conveyor line body are respectively located on both sides of the second conveyor line body in the Y direction; one layout machine is correspondingly configured at the output side of every two battery string welders, and two layout robots are configured in each layout machine for simultaneous layout.

5. The photovoltaic module production line according to claim 4, characterized in that: A total of eight battery string welders and four layout machines are provided in the welding area.

6. The photovoltaic module production line according to claim 2, wherein: A commutation mechanism is arranged at the position on the first conveyor line body for docking with the layout machine. The layout machine outputs the first-layer glass with the battery string laid out along the long side in the Y direction onto the first conveyor line body, and then horizontally commutes through the commutation mechanism, outputs the first-layer glass along the long side in the X direction into the battery string end welder, and then inputs it into the pasting and laying area for subsequent processes.

7. The photovoltaic module production line according to claim 2, characterized in that: A first commutation conveying mechanism is arranged at the output end of the first-layer adhesive film laying machine, and a second commutation conveying mechanism is arranged at the input end of the second conveyor line body; The one-layer adhesive film laying machine outputs one-layer glass with one-layer adhesive film laid along the long side in the reverse X direction. After being horizontally reversed and adjusted by the first reversing conveyor mechanism, it outputs one-layer glass with one-layer adhesive film laid along the short side in the Y direction. The second reversing conveyor mechanism receives one-layer glass input along the short side in the Y direction, horizontally reverses and adjusts it, and then outputs one-layer glass along the long side in the reverse X direction onto the second conveyor line body.

8. The photovoltaic module production line according to claim 1, wherein: The small-piece long-side rubber strip placing machine includes a component conveyor line, a long-strip cutting and feeding module, a long-strip handling and placing module, a small-piece cutting and feeding module, and a small-piece handling and placing module arranged above the component conveyor line.

9. The photovoltaic module production line according to claim 1, characterized in that: The pasting and laying area further includes a lead bending and high-temperature cloth placing machine, a pre-EL detector, and an edge sealing machine arranged in sequence along the X direction. The lead bending and high-temperature cloth placing machine places high-temperature cloth at the lead and bends and flattens the lead. The pre-EL detector includes several layers of detection stations, and the edge sealing machine includes several layers of edge sealing stations. A first lifting stack line body is configured on the input side of the pre-EL detector, and a second lifting stack line body is configured on the output side of the edge sealing machine.

10. The photovoltaic module production line according to claim 1, characterized in that: A third lifting stack line body is arranged between the small-piece long-side rubber strip placing machine and the short-side rubber strip placing machine; a fourth lifting stack line body is arranged between the backplane cutting and laying machine and the laminator.

11. The photovoltaic module production line according to claim 9, wherein: The conveyor line body at the pre-EL detector is a reversing conveyor line with a reversing conveying function; a sixth lifting stack line body is arranged on the reverse X direction side of the pre-EL detector; the pasting and laying area is also equipped with an AGV transfer cart. When the cache quantity of the sixth lifting stack line body reaches the set value, the defective products are taken out by the AGV transfer cart and transported to the repair area for centralized repair processing. After passing the repair, they are sent back into the sixth lifting stack line body by the AGV transfer cart and returned to the pre-EL detector through the sixth lifting stack line body.

12. The photovoltaic module production line according to claim 1, wherein: The second glass loading area includes a second glass loading machine and a third reversing conveyor line. The second glass loading machine outputs two-layer glass along the long side in the X direction. After being reversed by the third reversing conveyor, it outputs two-layer glass along the short side in the Y direction. A fifth lifting stack line body is arranged on the Y direction output side of the third reversing conveyor line.

13. The photovoltaic module production line according to claim 1, wherein: The second glass loading area includes a second glass loading machine and a gap film pasting device arranged on the output side of the second glass loading machine. The gap film pasting device includes a long-side gap film feeding and pasting unit, a short-side gap film feeding and pasting unit, a first handling mechanism, and a second handling mechanism.

14. The photovoltaic module production line according to claim 13, characterized in that: The second glass loading machine outputs the second glass along the long side in the X direction to the second glass loading station. The long-side gap film feeding and pasting unit is arranged on the X-direction output side of the second glass loading station. The first handling mechanism transports the second glass from the second glass loading station along the X direction to the long-side gap film feeding and pasting unit for automatic pasting of the long-side gap film. The short-side gap film feeding and pasting unit is arranged on one side in the Y direction of the long-side gap film feeding and pasting unit and close to the laminator. The second handling mechanism horizontally reverses and transports the second glass from the long-side gap film feeding and pasting unit to the short-side gap film feeding and pasting unit. The laminating robot in the laminator sucks the second glass with the gap film pasted on the lower surface from the short-side gap film feeding and pasting unit and covers it on the first glass to complete lamination.

15. A photovoltaic module production process implemented based on the photovoltaic module production line according to claim 2, characterized in that: It includes the following steps: S1. The first glass loading area completes the loading, inkjet coding, and laying of the first adhesive film for the first glass: The first glass loading machine loads the first glass onto the production line, sprays the information code at the specified position of the first glass through the inkjet coder, and lays the adhesive film on the first glass through the first adhesive film laying machine. S2. The first glass loading area outputs the first glass along the short side in the Y direction. After horizontal reversal through the reversing conveyor mechanism, it is transported along the long side in the reverse X direction to the second conveyor line body and enters the welding area. S3. In the welding area, the battery string welder outputs the battery string along the Y direction. The first glass is transported to the layout machine through the second conveyor line body. The layout machine arranges the battery strings on the first glass in a set manner. The first glass after layout is output along the long side in the Y direction to the first conveyor line body, and then transported along the X direction to the battery string end welder to weld the bus bars, connecting all the battery strings together, and continuing to be transported along the long side in the X direction to the pasting and laying area. S4. In the pasting and laying area, according to the process requirements of different types of photovoltaic modules, multiple or all of the processes such as tape pasting, long-strip placement, small-piece placement, short-strip placement, second adhesive film laying, backsheet laying, lamination, high-temperature cloth placement, lead bending, EL detection, and edge sealing are completed in sequence. S5. The photovoltaic modules output from the pasting and laying area are further diverted into multiple laminators for lamination operations.

16. The photovoltaic module production process according to claim 15, characterized in that: In step S4, if lamination operation is included, at the lamination operation station, the second glass is loaded through the second glass loading area.

17. The photovoltaic module production process according to claim 16, characterized in that: If it is necessary to paste the gap reflective film on the lower surface of the second glass, the automatic pasting of the long-side gap film and the short-side gap film is completed through the gap film pasting equipment.

18. A photovoltaic module, characterized in that: It is produced by using the photovoltaic module production line described in claim 1 or by using the photovoltaic module production process described in claim 15.

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