Method for double-station single-laser welding of photovoltaic module junction box

Abstract

The invention discloses a method for double-station single-laser welding of a photovoltaic module junction box. The method comprises the following steps that machining point positions are arranged according to the sizes of welding areas of a first station and a second station on the left side and the right side of the junction box; every two correspondingly-arranged machining point positions in the first station and the second station are set as a set, a single laser is adopted for conducting swing welding on each machining point position, the single laser emits light at the machining point position of the first station, and after welding of the machining point position is completed, the single laser is used for conducting swing welding on the machining point position of the second station. The single laser jumps to the machining point positions, located at the second station, of the same set through a galvanometer for welding, light is turned off after welding is completed, and welding of one set of machining point positions is completed; then, the galvanometer skips to the other set of machining points for light emitting welding, and the operation is repeated till welding of all the machining points is completed; and the welding operation is repeated, and each machining point position is repeatedly welded for multiple times. According to the method, the time required for welding can be effectively shortened, and meanwhile the welding effect and the welding yield are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of laser welding of photovoltaic module junction boxes, and in particular to a method for double-station single-laser welding of photovoltaic module junction boxes. Background Art

[0002] The essence of laser welding of photovoltaic module junction boxes is to perform hot melt welding on two welding materials, which requires fast welding speed and high strength.

[0003] Existing laser welding of photovoltaic module junction boxes uses a single laser beam source, resulting in long welding times and difficulty meeting speed requirements. Furthermore, current welding processes suffer from difficulties in improving yield and poor stability. The current welding process is susceptible to the effects of previous processes. When defects in previous processes result in residual adhesive, impurities, or dirt on the busbars and junction box base, this directly impacts the welding process, necessitating manual re-inspection and repair welding.

[0004] In the current industry-wide emphasis on cost reduction and efficiency improvement, the existing single-laser welding process for processing a single junction box only emits as many laser beams as the total number of welds, resulting in long processing times and fluctuating yield rates, which cannot meet production needs and subsequent speed-up expectations. Therefore, a welding method that can improve welding efficiency and yield is needed. Summary of the Invention

[0005] In order to solve the problems existing in the above-mentioned prior art, the purpose of the present invention is to provide a method for welding photovoltaic module junction boxes with a double-station single laser, which can effectively shorten the time required for welding and improve the welding yield and stability.

[0006] The present invention provides the following technical solutions:

[0007] The present invention provides a method for double-station single laser welding of photovoltaic module junction boxes, comprising the following steps:

[0008] S1. Set the welding drawing; set the processing points according to the size of the welding areas of the first and second stations on the left and right sides of the junction box; the processing points on the first station and the second station are set correspondingly;

[0009] S2, swing welding; set every two corresponding processing points in the first station and the second station as a group, use a single laser to perform swing welding on each processing point, the single laser emits light at the processing point of the first station, after the welding of the processing point is completed, the single laser jumps to the processing point of the same group located at the second station through the galvanometer to weld, after the welding is completed, the light is turned off, and the welding of one group of processing points is completed; then the galvanometer jumps to another group of processing points and performs light welding again, and the above operation is repeated until the welding of all processing points is completed;

[0010] S3, repeat step S2, and repeat welding for each processing point multiple times.

[0011] Furthermore, the present invention only needs to emit light once to complete the processing at two processing points, thereby achieving the technical effect of processing the first and second workstations at the same time.

[0012] Furthermore, by repeatedly welding each of the processing points multiple times, the cleaning effect of the laser can be amplified, and contamination on the busbar surface and the junction box surface caused by defects in the previous processing can be effectively removed, so that the equipment can weld normally, thereby improving the welding yield.

[0013] Preferably, each of the processing points is welded repeatedly 2-4 times.

[0014] Furthermore, the first workstation is a left workstation or a right workstation of the junction box, and each group of processing points can be welded in a welding sequence from left to right or from right to left.

[0015] Furthermore, the junction box is provided with a plurality of processing points, and the plurality of processing points can be welded in a top-down or bottom-up welding sequence.

[0016] Preferably, the multiple groups of processing points are arranged in a row at equal intervals, and the interval between two adjacent groups of processing points is 0.5mm-2.5mm.

[0017] Furthermore, the light output welding power of the swing welding is set to 45%-80% of the laser output power.

[0018] Furthermore, the light-emitting welding power during the swing welding of the last group of processing points is reduced by 5%-10% compared with the light-emitting welding power of the previous processing points.

[0019] Furthermore, the welding speed of the swing welding is 80 mm / s-250 mm / s.

[0020] Furthermore, in step S2, the speed at which the galvanometer jumps between the same set of processing points is 2000 mm / s-4000 mm / s.

[0021] Furthermore, the swing welding is performed in a wave-shaped or spiral-shaped manner.

[0022] Furthermore, the oscillation frequency of the oscillation welding is 500Hz-1200Hz.

[0023] Through the above scheme design, the present invention has the following effects:

[0024] The dual-station single-laser welding method for photovoltaic module junction boxes of the present invention uses a single laser to process two processing points of the junction box within one light output, which can effectively reduce the number of light outputs, shorten the time required for welding while ensuring the welding effect, and effectively improve the production efficiency of junction box welding; repeated welding is performed on each processing point, which effectively reduces the impact of problems in the previous process on the welding effect, improves production efficiency and welding yield, and can meet the current photovoltaic market requirements for production time and production yield. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0026] Figure 1 This is the processing point arrangement diagram provided in Example 1 of the present invention.

[0027] Figure 2 This is the processing point arrangement diagram provided in Example 3 of the present invention.

[0028] Figure 3 This is a welding effect diagram provided in Example 1 of the present invention.

[0029] Figure 4 This is a welding effect diagram provided in Example 2 of the present invention.

[0030] Figure 5 This is a welding effect diagram provided in Example 3 of the present invention.

[0031] Figure 6 This is a welding effect diagram provided for Example 4 of the present invention.

[0032] Figure 7 This is a welding effect diagram provided for Example 5 of the present invention.

[0033] Figure 8 This is a welding effect diagram provided for Example 6 of the present invention.

[0034] Figure 9 This is a diagram showing the welding effect of a junction box with residual dirt provided in Example 1 of the present invention.

[0035] Figure 10 This is a diagram showing the welding effect of a junction box with residual dirt provided in Comparative Example 1 of the present invention.

[0036] Figure 11 This is a welding effect diagram provided for comparative example 7 of the present invention.

[0037] Figure 12This is a welding effect diagram provided for comparative example 8 of the present invention.

[0038] Figure 13 This is a welding effect diagram provided for comparative example 9 of the present invention.

[0039] Figure 14 This is a welding effect diagram provided for comparative example 10 of the present invention.

[0040] Figure 15 This is a welding effect diagram provided for comparative example 11 of the present invention.

[0041] Figure 16 This is a welding effect diagram provided for comparative example 12 of the present invention.

[0042] Figure 17 This is a welding effect diagram provided for comparative example 13 of the present invention. DETAILED DESCRIPTION

[0043] The following will clearly and completely describe the technical solutions of the present invention in conjunction with the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of them. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention without making any creative efforts shall fall within the scope of protection of the present invention.

[0044] It will be understood that when used in this specification and the appended claims, the terms “comprises” and “comprising” indicate the presence of described features, integers, steps, operations, elements and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or groups thereof.

[0045] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the present invention. As used in the specification and appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly indicates otherwise.

[0046] Example 1

[0047] A method for double-station single laser welding of photovoltaic module junction boxes, comprising the following steps:

[0048] S1. Set welding drawing file; Figure 1As shown, three horizontal processing points are set at the first and second stations, respectively, based on the welding area sizes of the first and second stations on the left and right sides of the junction box. The three horizontal processing points in each station are arranged in parallel with equal spacing. The processing point length is 4 mm, and the spacing between adjacent processing points in each station is 1.5 mm. The swing mode is set to wave swing, and the swing frequency is 800 Hz.

[0049] S2. Swing welding: Each pair of corresponding processing points in the first and second stations is grouped together, i.e., each row of processing points constitutes a group. In this embodiment, three groups are provided from top to bottom. A single 1500W laser is used to perform swing welding on these three groups of processing points from top to bottom. The laser power for the first two groups is set to 1000W, and the laser power for the last group is set to 950W. The welding speed of the single laser is set to 180mm / s. A single laser emits light at the top processing point of the first workstation. After the welding of this processing point is completed, the single laser jumps to the processing point of the same group at the second workstation through the galvanometer for welding. After welding is completed, the light is turned off to complete the welding of a group of processing points; then the galvanometer jumps to the processing point of the middle group at the first workstation for further light welding. After welding is completed, it jumps to the processing point of the same group at the second workstation for welding. After welding is completed, the light welding power is adjusted to 900W, and the galvanometer jumps to the processing point of the last group at the first workstation for further light welding. After welding is completed, it jumps to the processing point of the same group at the second workstation for welding to complete the welding of all processing points.

[0050] S3. Repeat the welding steps of step S2 three times, that is, weld each processing point three times to complete the welding of the entire junction box.

[0051] Specifically, the speed at which the galvanometer jumps in the same set of processing points is 3000 mm / s.

[0052] Example 2

[0053] A method for double-station single laser welding of photovoltaic module junction boxes, comprising the following steps:

[0054] S1. Set up a welding diagram. Based on the size of the welding area at the first station on the left side of the junction box and the second station on the right side, set a circular processing point at each station. Set the swing mode to spiral swing and the swing frequency to 1200 Hz.

[0055] S2. Swing welding: Each pair of corresponding processing points in the first and second stations is grouped together. In this embodiment, only one group is used. A 1500W single laser is used for swing welding of the processing points. The laser power is set to 675W, and the welding speed is 80mm / s. The single laser emits light at the processing point in the first station. After welding is completed at this processing point, the single laser jumps to the processing point in the same group at the second station via a galvanometer to weld. After welding is completed, the laser is turned off.

[0056] S3. Repeat the welding steps of step S2 twice, that is, weld each processing point twice to complete the welding of the entire junction box.

[0057] Specifically, the speed at which the galvanometer jumps in the same set of processing points is 2000 mm / s.

[0058] Example 3

[0059] A method for double-station single laser welding of photovoltaic module junction boxes, comprising the following steps:

[0060] S1. Set welding drawing file; Figure 2 As shown, four horizontal processing points are set at the first and second stations, respectively, based on the welding area sizes of the first and second stations on the left and right sides of the junction box. The four horizontal processing points in each station are arranged in parallel and at equal intervals. The processing point length is 8 mm, and the spacing between adjacent processing points in each station is 2.5 mm. The swing mode is set to wave swing, and the swing frequency is 1000 Hz.

[0061] S2, swing welding; set every two corresponding processing points in the first and second stations as a group, that is, each row of processing points is a group. In this embodiment, there are four groups from top to bottom. Use a 1500W single laser to perform swing welding on the four groups of processing points from top to bottom. Set the light output welding power of the first two groups of processing points to 1200W, and the light output welding power of the last group to 1080W. The welding speed of the single laser is 250mm / s. The single laser emits light at the top processing point of the first station. After the welding of this processing point is completed, the single laser jumps to the processing point of the same group at the second station through the galvanometer to weld. After the welding is completed, the light is turned off to complete the welding of one group of processing points; then the galvanometer jumps to the processing point of the second group to weld, and the above operation is repeated until the welding of the first three groups is completed. Adjust the laser welding power to 1080W, jump the galvanometer to the processing point of the last group at the first station to perform laser welding, and after welding, jump to the processing point of the same group at the second station to complete welding of all processing points.

[0062] S3. Repeat the welding steps of step S2 4 times, that is, weld each processing point 4 times to complete the welding of the entire junction box.

[0063] Specifically, the speed at which the galvanometer jumps within the same set of processing points is 4000 mm / s.

[0064] Example 4

[0065] The only difference between this embodiment and embodiment 1 is that: this embodiment has two groups of processing points, and the spacing between the two groups of processing points is 0.5 mm.

[0066] Example 5

[0067] The only difference between this embodiment and embodiment 1 is that: the first workstation in this embodiment is the workstation on the right side of the junction box, and the second workstation is the workstation on the left side of the junction box, that is, the welding order within each group of processing points in this embodiment is from right to left; the welding between each group of processing points in this embodiment is carried out in a bottom-up order, and the last group of processing points is the processing points located at the top.

[0068] Example 6

[0069] The only difference between this embodiment and embodiment 1 is that the light welding power of the last group of processing points is 980W.

[0070] In order to verify the technical effect of the present invention, welding tests were carried out on the method of double-station single laser welding of photovoltaic module junction boxes of Example 1-6, and the welding effect, welding yield and welding time were tested respectively. Comparative Examples 1-6 were set up correspondingly on the basis of Example 1-6. The processing parameters of Comparative Examples 1-6 and Example 1-6 were consistent. The only difference was that a single laser single-point light-emitting welding method was used for welding in step S2, that is, a single laser emitted light at each processing point, and the light was turned off after welding one processing point. After jumping to another processing point, the above steps were continued until all processing points were welded. After welding was completed, the welding was repeated for the number of welding times corresponding to Example 1-6. The test results of Example 1-6 were compared with those of Comparative Examples 1-6. The results are shown in Table 1, where the single component welding time refers to the total time from feeding to discharging of the entire component. The welding effect diagram of Example 1-6 is shown in Figure 1. Figure 3-8 shown.

[0071] Table 1 Welding test results of Examples 1-6 and Comparative Examples 1-6

[0072]

[0073] As shown in Table 1, the present invention's dual-station single-laser welding method for photovoltaic module junction boxes utilizes a single laser for dual-station welding, enabling welding of two processing points with a single laser beam. Compared to existing single-laser single-point welding methods, this method significantly reduces welding time, achieves excellent welding results, and achieves a high welding yield. Further comparison reveals that the yield rates of Examples 1-6 are significantly improved compared to Comparative Examples 1-6. Given the bottleneck in single-laser single-point welding yield, even a 0.1% yield increase represents a significant improvement. Therefore, the present invention offers a significant advantage in improving welding yield rates.

[0074] In order to further verify the influence of the welding method of the present invention and the single laser single point welding method on the welding yield of the junction box, the methods of Example 1 and Comparative Example 1 were used to weld the junction box with residual dirt, and the welding effects were as follows: Figure 9 、 Figure 10 shown.

[0075] When residual dirt remains on the junction box, the method of the present invention still allows for a clear weld pool, demonstrating excellent welding results. However, when using single-laser single-point welding, the weld pool becomes invisible, resulting in a blackened appearance and a clear sign of a cold weld. Therefore, the method of the present invention significantly improves welding yield and stability, eliminating the need for manual post-weld inspection and repair welding, saving labor costs and achieving cost reduction and efficiency improvement.

[0076] Furthermore, in order to verify the influence of various parameters of the present invention on the final welding effect, comparative examples 7-11 were set based on Example 1, and comparative examples 12 and 13 were set based on Example 6. Comparative examples 7-13 are as follows:

[0077] Comparative Example 7

[0078] The only difference between this comparative example and the embodiment is that the light welding power of the last group of processing points is 1000W.

[0079] Comparative Example 8

[0080] The only difference between this comparative example and Example 1 is that the welding speed of the swing welding is 50 mm / s.

[0081] Comparative Example 9

[0082] The only difference between this comparative example and Example 1 is that the welding speed of the swing welding is 300 mm / s.

[0083] Comparative Example 10

[0084] The only difference between this comparative example and Example 1 is that all workstations were welded only once.

[0085] Comparative Example 11

[0086] The only difference between this comparative example and Example 1 is that welding is repeated 5 times at all workstations.

[0087] Comparative Example 12

[0088] The only difference between this comparative example and Example 6 is that the light-emitting welding power of the first two groups of processing points is 600W, and the light-emitting welding power of the last group is 570W.

[0089] Comparative Example 13

[0090] The only difference between this comparative example and Example 6 is that the light welding power of the first two groups of processing points is 1500W, and the light welding power of the last group is 1425W.

[0091] The welding effects of the above comparative examples 7-13 were observed. Figure 11-17 shown.

[0092] Comparing the welding results of Comparative Examples 7-13 with Examples 1 and 6 reveals that when the swing welding speed is outside the range of this application, the weld line is unsightly and suffers from an abnormal molten pool. Failure to repeat the welding process can lead to cold welds. Excessive repetitions can lead to severe thermal effects, making welding difficult. When the welding power is too low, the molten pool is shallow and difficult to observe. When the welding power is too high, the weld line becomes noticeably blackened and suffers from severe thermal effects.

[0093] In summary, the welding method of the present invention requires short welding time, has good welding effect, high yield and strong stability.

[0094] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in the present invention, and such modifications or substitutions are intended to be within the scope of protection of the present invention. Therefore, the scope of protection of the present invention shall be subject to the scope of protection of the claims.

Claims

1. A method for double-station single laser welding of photovoltaic module junction boxes, characterized in that: The following steps are involved: S1. Set the welding drawing; set the processing points according to the size of the welding areas of the first and second stations on the left and right sides of the junction box; the processing points on the first station and the second station are set correspondingly; S2, swing welding; every two corresponding processing points in the first and second stations are set as a group, and a single laser is used to perform swing welding on each processing point. The single laser emits light at the processing point of the first station. After the welding of the processing point is completed, the single laser jumps to the processing point of the same group located at the second station through the galvanometer to weld. After the welding is completed, the light is turned off to complete the welding of one group of processing points; then the galvanometer jumps to another group of processing points to emit light and weld again, and the above operation is repeated until the welding of all processing points is completed; S3, repeat step S2, and repeat welding for each processing point multiple times.

2. The method for double-station single laser welding of photovoltaic module junction boxes according to claim 1, characterized in that: Each processing point is welded repeatedly 2-4 times.

3. The method for double-station single laser welding of photovoltaic module junction boxes according to claim 1, characterized in that: The first workstation is the left workstation or the right workstation of the junction box, and each group of processing points is welded in a welding sequence from left to right or from right to left.

4. The method for welding a photovoltaic module junction box using a double-station single laser as claimed in claim 1, wherein: The junction box is provided with a plurality of processing points, and the plurality of processing points can be welded in a top-down or bottom-up welding sequence.

5. The method for double-station single laser welding of photovoltaic module junction boxes according to claim 4, characterized in that: The light output welding power of the swing welding is set to 45%-80% of the laser output power.

6. The method for double-station single laser welding of photovoltaic module junction boxes according to claim 5, characterized in that: The laser welding power during the swing welding of the last set of processing points is reduced by 5%-10% compared with the laser welding power of the previous processing points, that is, the laser welding power of the last two processing points is 35%-75% of the laser output power.

7. The method for double-station single laser welding of photovoltaic module junction boxes according to claim 1, characterized in that: The welding speed of the swing welding is 80 mm / s-250 mm / s.

8. The method for double-station single laser welding of photovoltaic module junction boxes according to claim 1, characterized in that: In the step S2, the speed at which the galvanometer jumps between the same set of processing points is 2000 mm / s-4000 mm / s.

9. The method for double-station single laser welding of photovoltaic module junction boxes according to claim 1, characterized in that: The swing welding is performed in a wave-shaped or spiral-shaped manner.

10. The method for double-station single laser welding of photovoltaic module junction boxes according to claim 1, characterized in that: The oscillation frequency of the oscillation welding is 500Hz-1200Hz.

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