Photovoltaic module four-side sealing butyl rubber lacking detection equipment and detection method

Abstract

The invention relates to photovoltaic module four-side sealing butyl rubber lacking detection equipment and a detection method, and relates to the technical field of photovoltaic module detection. Comprising a shell, a feeding table, a detection building and a detection unit. According to the detection building, a framework is connected with a plurality of layered and stacked bearing tables, and each bearing table forms a rectangular structure through spliced bearing rods and is provided with a pressure sensor and a digital label. The detection unit comprises a driving assembly, a camera and a detection light source and can move along the edge of the photovoltaic assembly for imaging detection. The equipment is combined with a specific wave band light source and a camera imaging technology, butyl rubber and an EVA film are accurately distinguished, and rubber shortage detection is completed. The device achieves the effect of efficiently and accurately detecting the lack of butyl rubber for sealing the four sides of the photovoltaic module, and meanwhile, assists an operator in processing an NG piece through a three-color lamp and an interaction screen, thereby improving the automation and reliability of the detection process.

Description

Technical Field

[0001] The present application relates to the technical field of photovoltaic module detection, and in particular to a device and method for detecting the lack of butyl glue for sealing the four sides of a photovoltaic module. Background Art

[0002] As core components of solar power generation systems, the performance and reliability of photovoltaic modules directly impact the overall system's operating efficiency and lifespan. Sealing technology is crucial in their manufacturing to ensure long-term, stable operation. Good sealing effectively prevents harmful substances like moisture and oxygen from invading the module interior, preventing cell aging or damage. Currently, butyl rubber, a highly effective sealing material, is widely used in the photovoltaic field. It not only offers excellent sealing and aging resistance, but also maintains stable performance in extreme climates. Its compatibility with encapsulation materials like EVA film makes it a popular choice for edge sealing in photovoltaic modules.

[0003] In actual production, to ensure the sealing effectiveness of photovoltaic modules, manual visual inspection or simple tool-assisted inspection methods are often used to check the sealing of butyl adhesive. For example, the width and uniformity of the butyl adhesive can be visually observed, or the thickness can be measured with a caliper to ensure it meets the requirements. In addition, some companies use ultraviolet light to observe the fluorescence reaction of the butyl adhesive at specific wavelengths to determine whether there is any adhesive deficiency. However, these methods generally suffer from low detection accuracy, low efficiency, and significant human factors.

[0004] Existing detection methods are unable to meet the high sealing quality requirements of photovoltaic modules in large-scale production. In particular, during the high-temperature lamination process, butyl adhesive can easily be squeezed out of the module edges, exposing the EVA film on the backing, increasing the risk of water intrusion during subsequent use. Therefore, a technology that can accurately and efficiently detect butyl adhesive deficiencies on the four edges of photovoltaic modules is urgently needed to improve product quality and reduce production costs. Summary of the Invention

[0005] In order to solve the above problems, the present application provides a device and method for detecting the lack of butyl glue in the four-side sealing of photovoltaic modules.

[0006] A device for detecting butyl glue deficiency in the four-side sealing of photovoltaic modules comprises a shell and a loading platform. A detection building and a detection unit are arranged in the shell. The detection building comprises a skeleton and several bearing platforms. The skeleton connects the several bearing platforms into a whole so that the several bearing platforms are stacked in layers. A plurality of detection units are provided, and the several detection units correspond one-to-one to the several bearing platforms respectively. The bearing platforms are formed by splicing a plurality of bearing rods and are rectangular in shape. A pressure sensor is installed on the top of the bearing rod, and the bearing rod is also marked with a digital label. The detection unit comprises a drive assembly, a camera and a detection light source. The drive assembly drives the camera and the detection light source to move along the edge of the photovoltaic module.

[0007] By adopting the above technical solution, it is possible to achieve efficient detection of butyl rubber deficiency on the four sides of photovoltaic modules. By stacking several supporting platforms in layers and cooperating with corresponding detection units, multiple photovoltaic modules can be inspected at the same time, which improves the detection efficiency. The pressure sensor installed on the top of the supporting rod can monitor in real time whether the photovoltaic module is placed properly and assist in judging the status of the module after the inspection is completed. The camera in the detection unit works in conjunction with the detection light source, using a light source of a specific wavelength band to illuminate the edge of the photovoltaic module, and combining the color difference of butyl rubber and EVA film in the imaging to accurately identify whether there is a lack of glue. The digital labels marked on the supporting rod facilitate the positioning and management of each photovoltaic module, improving the traceability and operational convenience of the inspection process.

[0008] Preferably, an elevator is provided at the bottom of the inspection building for driving the inspection building up and down.

[0009] By adopting the above technical solution, an elevator is installed at the bottom of the inspection building to ensure that the load-bearing platform on each floor is precisely aligned with the inspection unit, thereby improving inspection efficiency and accuracy.

[0010] Preferably, the shell includes a door, an interactive screen is provided on the door, and a three-color light is provided on the top of the shell.

[0011] By adopting this technical solution, the enclosure includes a door with an interactive screen and a tri-color light on top of the enclosure, enabling human-machine interaction and status notification. The interactive screen allows operators to view detection information and the numerical identification of abnormal platforms, improving operational convenience. The tri-color light visually indicates the equipment's operating status or abnormal conditions through color changes, facilitating rapid response and resolution.

[0012] Preferably, it further comprises a conveying platform, the shell is provided with a loading port, and one end of the conveying platform extends into the loading port.

[0013] By adopting the above technical solution, the setting of the conveyor platform realizes the automatic loading and unloading of photovoltaic modules, improves the detection efficiency and reduces manual intervention.

[0014] A method for detecting butyl adhesive deficiency in four-side sealing of photovoltaic modules comprises the following steps: S1, loading, the conveyor platform transports multiple photovoltaic modules in a batch to the loading platform on each floor, and then the elevator lifts the top of the inspection building to the inspection position; S2, detection, taking pictures of the edges of the photovoltaic modules through the camera; S3, NG parts processing, manually remove NG parts; S4, unloading, transporting out from the conveyor along the original route.

[0015] By adopting the above technical solution, the method can process multiple photovoltaic modules in batches, thereby improving detection efficiency.

[0016] Preferably, in S1, the loading step, a photovoltaic module is placed on each supporting platform, and the elevator lifts the top of the inspection building so that each supporting platform is aligned with the inspection unit.

[0017] Preferably, in S2, the detection step, the device simultaneously detects that all pressure sensors have pressure signals, and then starts the camera and light source, and the driving component drives the camera and light source to move simultaneously along the edge of the photovoltaic module; the light source is used to illuminate the edge of the photovoltaic module, and the butyl rubber will appear black in the camera image, and the EVA film will appear blue in the camera image. If the edge image of the photovoltaic module is all black butyl rubber, it is judged as an OK part; if the blue EVA film can be seen in the edge image of the photovoltaic module, it is judged as an NG part.

[0018] Preferably, in S2, the detection step, the wavelength range of the light source is 200nm-500nm.

[0019] Preferably, in S3, the NG parts processing step, if one or more NG parts appear in the same batch, the three-color light will light up, the digital label of the carrier platform will be displayed on the interactive screen, and the operator will manually open the box door to take out the corresponding NG parts; after the NG parts are taken out, the pressure sensor on the corresponding carrier platform loses pressure sensing, the operator closes the box door, and after the equipment detects that the box door is closed, the three-color light will go out, and the conveyor will transport the remaining OK parts out along the same route; if there are no NG parts in the same batch of photovoltaic modules, skip S3 and go directly to S4.

[0020] Preferably, in S4, the unloading step, the elevator drives the inspection building to descend, and the edge of the photovoltaic module extends a certain distance outside the supporting platform. The extended part of the photovoltaic module will contact the conveying platform when descending and be dragged out of the supporting platform by the conveying platform. The corresponding pressure sensor loses the pressure sensing signal. When the signals of all the force transmission sensors disappear, the equipment determines that the inspection of a batch of photovoltaic modules is completed, and generates and stores an inspection report based on the inspection results of this batch. The inspection report includes photos taken of the photovoltaic modules.

[0021] By adopting the above technical solution, the edge of the photovoltaic module is photographed and imaged by a camera, and combined with the illumination of a specific light source, the imaging colors of butyl rubber and EVA film can be accurately distinguished, thereby effectively judging whether there is a glue shortage problem at the edge of the photovoltaic module, thereby improving the detection accuracy; for NG parts that fail the inspection, they are manually removed for processing, ensuring the continuity of the inspection process while avoiding the complexity of the equipment; the precise positioning and layered inspection of photovoltaic modules in the inspection equipment avoids mutual interference and improves the inspection accuracy; the coordinated use of the camera and the light source can clearly distinguish the color difference of butyl rubber and EVA film in the imaging, where butyl rubber appears black and EVA film appears blue, thereby achieving the goal of photovoltaic module detection. Visual judgment of the sealing status of the edge of the component; when NG parts are detected, the three-color light lights up and the digital label of the carrier table is displayed on the interactive screen, which makes it easy for operators to quickly locate the problem components and improve processing efficiency; after the box door is closed, the three-color light is automatically turned off and the conveyor table is started to realize automatic control, reduce human intervention, and ensure the continuity of the inspection process; use pressure sensors to monitor the removal status of photovoltaic components. When all pressure sensor signals disappear, the equipment can accurately determine that the inspection of a batch has been completed, which improves the intelligence level of the inspection process; automatically generate and store inspection reports containing photos, providing a reliable basis for subsequent quality traceability and analysis, and enhancing the verifiability and credibility of the inspection results.

[0022] In summary, this application includes at least one of the following beneficial technical effects: 1. The camera and light source of a specific wavelength in the detection unit, combined with a pressure sensor, can accurately distinguish the imaging characteristics of butyl rubber and EVA film, enabling precise detection of butyl rubber deficiency on the four sides of the photovoltaic module seal, effectively avoiding the risk of water ingress caused by exposed EVA film. 2. The multi-layer stacked carrier platform works in conjunction with the corresponding detection units to simultaneously inspect multiple photovoltaic modules, significantly improving inspection efficiency and meeting large-scale production needs; 3. Combined with the interactive screen, three-color light and pressure sensor feedback, it can realize the rapid positioning and processing of NG parts, reduce human interference, and ensure the efficiency and reliability of the inspection process. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a schematic diagram of a qualified photovoltaic module; Figure 2 This is a schematic diagram of unqualified photovoltaic modules; Figure 3 It is a three-dimensional view of the detection equipment; Figure 4 It is a side view of the specific structure of the detection equipment; Figure 5 It is a three-dimensional view of the specific structure of the inspection building and inspection unit.

[0024] Explanation of the accompanying drawings: 10, shell; 110, box door; 120, three-color light; 130, interactive screen; 20, conveying platform; 1, detection building; 11, carrying platform; 12, carrying rod; 13, pressure sensor; 14, skeleton; 2, detection unit; 21, driving assembly; 22, camera; 23, light source; 3, elevator; 4, glass; 5, butyl rubber; 6, EVA film. DETAILED DESCRIPTION

[0025] The following is combined with Figure 1-5 This application is described in further detail.

[0026] In the description of the invention, it should be understood that descriptions involving orientations, such as up, down, front, back, left, right, etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, they cannot be understood as limitations on the invention.

[0027] The inventors of this application have found that existing detection methods are difficult to meet the high requirements for the sealing quality of photovoltaic modules in large-scale production. In particular, during the high-temperature lamination process, the butyl rubber 5 is easily squeezed out of the edge of the module, resulting in the exposure of the adhesive EVA film 6, thereby increasing the risk of water ingress during the later use of the module. To this end, the embodiment of this application discloses a device for detecting the lack of butyl rubber in the four-side sealing of photovoltaic modules, referring to Figure 3 、 Figure 4 and Figure 5 , including a shell 10 and a loading platform. The shell 10 is provided with an inspection building 1 and an inspection unit 2. The inspection building 1 includes a skeleton 14 and several bearing platforms 11. The skeleton 14 connects the several bearing platforms 11 into a whole, so that the several bearing platforms 11 are stacked in layers. There are multiple inspection units 2, and the several inspection units 2 correspond to the several bearing platforms 11 one by one. The bearing platform 11 is formed by splicing a plurality of bearing rods 12, and the shape is rectangular. The plurality of bearing rods 12 are spliced to form a modular design, which is convenient for adjusting the size and shape of the bearing platform 11 according to actual needs. A pressure sensor 13 is installed on the top of the bearing rod 12 to detect whether the photovoltaic module is placed in place. The bearing rod 12 is also marked with digital numbers to facilitate the operator to accurately position it.

[0028] The detection unit 2 includes a drive assembly 21, a camera 22, and a detection light source 23. The drive assembly 21 drives the camera 22 and the detection light source 23 to move along the edge of the photovoltaic module. In the embodiment of the present application, the drive assembly 21 is a screw assembly. The camera 22 is used to capture images of the edge of the photovoltaic module, and the detection light source 23 is used to provide lighting conditions. The illumination of the light source 23 causes the butyl rubber 5 and the EVA film 6 to appear different colors in the imaging. The wavelength range of the light source 23 is 200nm-500nm. At this time, the butyl rubber 5 will appear black in the imaging of the camera 22, and the EVA film 6 will appear blue. If the edge of the photovoltaic module is imaged with black butyl rubber 5, it is judged to be an OK part; if the blue EVA film 6 can be seen, it is judged to be an NG part.

[0029] A lift 3 is installed at the bottom of the inspection building 1 to adjust its height and align it with the inspection unit 2, ensuring that the inspection unit 2 is accurately aligned with the edge of the photovoltaic module. The housing 10 includes a door 110, which is equipped with an interactive screen 130. This screen displays test results and operation prompts, allowing operators to monitor the progress of the test in real time and take appropriate actions. A three-color light 120 is installed at the top of the housing 10 to indicate the test status.

[0030] The device for detecting the lack of glue in the butyl glue 5 for sealing the four sides of photovoltaic modules also includes a conveyor platform 20. The shell 10 is provided with a loading port. One end of the conveyor platform 20 extends into the loading port, and the other end is connected to the production line, thus realizing seamless connection between the detection equipment and the production line. The conveyor platform 20 adopts a belt transmission method, which is suitable for the transportation of lightweight photovoltaic modules, and the belt has a large adhesion. In addition, during the detection process, the conveyor platform 20 can also be used to assist in unloading. When the detection is completed, the elevator 3 drives the detection building 1 to descend, and the edge of the photovoltaic module will extend out of the supporting platform 11 and contact the conveyor platform 20. The conveyor platform 20 drags the photovoltaic module out of the supporting platform 11, and the corresponding pressure sensor 13 loses the pressure sensing signal.

[0031] The embodiment of the present application also discloses a method for detecting the lack of butyl glue for sealing the four sides of a photovoltaic module, based on a device for detecting the lack of butyl glue for sealing the four sides of a photovoltaic module, referring to Figure 1-Figure 5 , including the following steps: S1, loading, the conveyor 20 transports a batch of multiple photovoltaic modules to the supporting platform 11 on each floor, and then the elevator 3 lifts the inspection building 1 to the inspection position; S2, detection, taking pictures and imaging the edge of the photovoltaic module through the camera 22; S3, NG parts processing, manually remove NG parts; S4, unloading, and transporting out from the conveyor 20 along the original route.

[0032] In S1 , the loading step, a photovoltaic module is placed on each supporting platform 11 , and the elevator 3 lifts up the inspection building 1 so that each supporting platform 11 is aligned with the inspection unit 2 .

[0033] In S2, the detection step, the device simultaneously detects that all pressure sensors 13 have pressure signals, and then starts the camera 22 and the light source 23. The driving component 21 drives the camera 22 and the light source 23 to move simultaneously along the edge of the photovoltaic module; the light source 23 is used to illuminate the edge of the photovoltaic module, and the butyl rubber 5 will appear black in the image of the camera 22, and the EVA film 6 will appear blue in the image of the camera 22. If the image of the edge of the photovoltaic module is all black butyl rubber 5, it is judged as an OK part; if the blue EVA film 6 can be seen in the image of the edge of the photovoltaic module, it is judged as an NG part.

[0034] In step S2, detection, the wavelength range of the light source 23 is 200 nm-500 nm.

[0035] In S3, the NG parts processing step, if one or more NG parts appear in the same batch, the three-color light 120 lights up, and the digital label of the carrier 11 is displayed on the interactive screen 130. The operator manually opens the box door 110 to take out the corresponding NG parts; after the NG parts are taken out, the pressure sensor 13 on the corresponding carrier 11 loses pressure sensing, and the operator closes the box door 110. After the equipment detects that the box door 110 is closed, the three-color light 120 goes out, and the conveyor 20 transports the remaining OK parts out along the same route; if there are no NG parts in the same batch of photovoltaic modules, skip S3 and go directly to S4.

[0036] In S4, the unloading step, the elevator 3 drives the inspection building 1 to descend, and the edge of the photovoltaic module extends a distance outside the supporting platform 11. The extended part of the photovoltaic module will contact the conveying platform 20 when descending and be dragged out of the supporting platform 11 by the conveying platform 20. The corresponding pressure sensor 13 loses the pressure sensing signal. When the signals of all the force transmission sensors disappear, the equipment determines that the inspection of a batch of photovoltaic modules is completed, and generates and stores an inspection report based on the inspection results of this batch. The inspection report includes photos taken of the photovoltaic modules.

[0037] The implementation principle of the embodiment of the present application is as follows: through the design of the multi-layer support platform 11 and the introduction of the automated detection process, the simultaneous detection of multiple photovoltaic modules is achieved, which significantly improves the detection efficiency. The use of a light source 23 in a specific wavelength band makes the distinction between the butyl rubber 5 and the EVA film 6 more obvious, ensuring the accuracy of the detection results. Although the manual processing of NG parts retains manual intervention, it is limited to necessary links. Because under normal circumstances, the photovoltaic modules produced by photovoltaic module production equipment have a high yield rate. Usually, in the inspection of the vast majority of photovoltaic module batches, the results displayed are qualified. Manual processing of NG parts will not cause the operator to be overwhelmed. Therefore, this equipment provides a reliable guarantee for the high-quality production of photovoltaic modules.

[0038] The above are all preferred embodiments of the present application, and are not intended to limit the scope of protection of the present application. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the scope of protection of the present application.

Claims

1. A device for detecting butyl adhesive deficiency on four sides of photovoltaic modules, characterized by: A housing (10) and a loading platform, wherein a detection building (1) and a detection unit (2) are arranged in the housing (10), the detection building (1) comprises a skeleton (14) and a plurality of bearing platforms (11), the skeleton (14) connects the plurality of bearing platforms (11) into a whole, and the plurality of bearing platforms (11) are stacked in layers; The detection units (2) are provided in a plurality, and the plurality of detection units (2) correspond one-to-one to the plurality of supporting platforms (11); The bearing platform (11) is formed by splicing a plurality of bearing rods (12) and is rectangular in shape. A pressure sensor (13) is installed on the top of the bearing rod (12), and a numerical number is also marked on the bearing rod (12); The detection unit (2) comprises a driving component (21), a camera (22) and a detection light source (23); the driving component (21) drives the camera (22) and the detection light source (23) to move along the edge of the photovoltaic component.

2. The photovoltaic module four-side sealing butyl adhesive deficiency detection device according to claim 1, characterized in that: An elevator (3) for driving the inspection building (1) to move up and down is provided at the bottom of the inspection building (1).

3. The photovoltaic module four-side sealing butyl adhesive deficiency detection device according to claim 1, characterized in that: The housing (10) comprises a door (110), an interactive screen (130) is provided on the door (110), and a three-color light (120) is provided on the top of the housing (10).

4. The photovoltaic module four-side sealing butyl adhesive deficiency detection device according to claim 1, characterized in that: It also includes a conveying platform (20), the shell (10) is provided with a loading port, and one end of the conveying platform (20) extends into the loading port.

5. A method for detecting the lack of butyl adhesive in the four-side sealing of photovoltaic modules, based on a device for detecting the lack of butyl adhesive in the four-side sealing of photovoltaic modules, characterized in that: The steps include: S1, loading, a batch of multiple photovoltaic modules are transported to the supporting platform (11) on each floor by the conveyor (20), and then the inspection building (1) is lifted to the inspection position by the elevator (3); S2, detection, taking pictures and imaging the edge of the photovoltaic module through a camera (22); S3, NG parts processing, manually remove NG parts; S4, unloading, and transporting out from the conveyor (20) along the original route.

6. A method for detecting butyl adhesive deficiency in four-side sealing of photovoltaic modules according to claim 5, characterized in that: In step S1, loading, a photovoltaic module is placed on each carrier platform (11), and the lift (3) lifts up the inspection building (1) so that each carrier platform (11) is aligned with the inspection unit (2).

7. The method for detecting butyl adhesive deficiency in four-side sealing of photovoltaic modules according to claim 5, characterized in that: In step S2, the detection step, the device simultaneously detects that all pressure sensors (13) have pressure signals, and then starts the camera (22) and the light source (23). The driving component (21) drives the camera (22) and the light source (23) to move simultaneously along the edge of the photovoltaic component; the light source (23) is used to illuminate the edge of the photovoltaic component, and the butyl rubber (5) will appear black in the image of the camera (22), and the EVA film (6) will appear blue in the image of the camera (22). If the image of the edge of the photovoltaic component is all black butyl rubber (5), it is judged as an OK part; if the image of the edge of the photovoltaic component can see the blue EVA film (6), it is judged as an NG part.

8. A method for detecting butyl adhesive deficiency in four-side sealing of photovoltaic modules according to claim 7, characterized in that: In step S2, detection, the wavelength range of the light source (23) is 200nm-500nm.

9. The method for detecting butyl adhesive deficiency in four-side sealing of photovoltaic modules according to claim 5, characterized in that: In S3, the NG parts processing step, if one or more NG parts appear in the same batch, the three-color light (120) lights up, the digital number of the carrier (11) is displayed on the interactive screen (130), and the operator manually opens the box door (110) to take out the corresponding NG parts; after the NG parts are taken out, the pressure sensor (13) on the corresponding carrier (11) loses pressure sensing, the operator closes the box door (110), and after the equipment detects that the box door (110) is closed, the three-color light (120) goes out, and the conveyor (20) transports the remaining OK parts out along the same route; if there are no NG parts in the same batch of photovoltaic modules, S3 is skipped and S4 is directly entered.

10. The method for detecting butyl adhesive deficiency in four-side sealing of photovoltaic modules according to claim 5, characterized in that: In step S4, the unloading step, the elevator (3) drives the inspection building (1) to descend, and the edge of the photovoltaic module extends a distance outside the supporting platform (11). The extended portion of the photovoltaic module contacts the conveying platform (20) when descending and is dragged out of the supporting platform (11) by the conveying platform (20). The corresponding pressure sensor (13) loses the pressure sensing signal. When the signals of all the force transmission sensors disappear, the equipment determines that the inspection of a batch of photovoltaic modules is completed, and generates and stores an inspection report based on the inspection results of this batch. The inspection report includes photos taken of the photovoltaic modules.

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