Photovoltaic module series welding processing technology and series welding processing equipment thereof

Abstract

The invention relates to a series welding processing technology of a photovoltaic module in the technical field of series welding processing of the photovoltaic module. The series welding processing technology comprises the following steps: heating the bottom of a glass plate to melt and adhere an adhesive film on the upper surface; scribing and drying the finished battery piece to obtain an initial temperature; the visual positioning manipulator grabs a plurality of battery pieces, blows heat to maintain the temperature and accurately places the battery pieces on the molten adhesive film, and rapid bonding and fixing are realized by using heat; laying welding wires and then performing laser welding to form a battery string; the invention further relates to welding processing equipment which comprises a glass bearing plate feeding mechanism, a scribing and feeding mechanism, a sheet placing table, a manipulator, a rubberizing mechanism, a welding station provided with a wire drawing and distributing module and a discharging module. According to the invention, by integrating sheet placing and welding links, the occupied space of equipment is reduced; secondary carrying after welding is avoided, and the damage risk is reduced; and the production efficiency is improved by utilizing a manipulator multi-piece grabbing technology, a hot air temperature maintaining technology and a laser welding technology.

Description

Technical Field

[0001] The present invention relates to the technical field of battery cell string welding production, and in particular to a photovoltaic module string welding processing technology. Background Art

[0002] In the production process of photovoltaic modules, the efficiency and reliability of the cell string welding process are crucial. The traditional processing technology requires the welding and layout of the cell strings to be completed in stages. Specifically, the same string of cells is placed and transported to the first welding position for welding via a belt. The robot then grabs the welded cell strings and arranges them on the glass plate. After all the cell strings are arranged, they are transported to the second welding position for full-plate welding. This process requires two placement areas and corresponding welding stations, forming a "swing table-welding position-swing table-welding position" layout along the belt transmission direction, resulting in a large equipment footprint and low space utilization. At the same time, when the robot grabs the welded cell strings for secondary transportation, it must be careful to avoid damage to the welding position during the operation, which increases the operational risk and product defect rate. In addition, the traditional process of string-by-string placement, welding and waiting for layout is cumbersome, and the placement time of a single cell string is long. In addition, the secondary transportation and traditional welding technology (such as infrared heating) are slow, resulting in low overall production efficiency.

[0003] Therefore, how to solve the defects of traditional processes such as large equipment footprint, high operating risks, and low production efficiency has become an urgent problem that needs to be solved in the industry. Summary of the Invention

[0004] In order to overcome the problems of existing photovoltaic module string welding processing equipment occupying a large area, the secondary handling of battery strings easily damaging the welding position, the cumbersome and inefficient production process, and the slow speed of traditional welding technology, the present invention provides a photovoltaic module string welding processing technology and string welding processing equipment.

[0005] The technical solution of the present invention is as follows:

[0006] A photovoltaic module string welding process, comprising the following steps:

[0007] S1. Glass plate preparation and film treatment: providing a glass plate, covering the upper surface of the glass plate with a film, and heating the bottom of the glass plate to make the film in a molten and adhered state;

[0008] S2. Cell preparation: providing finished cell sheets coated with insulating adhesive, dicing the finished cell sheets into a number of smaller cells, and drying the cells during the dicing process so that the cells have an initial temperature;

[0009] S3, disposable array placement: Using a manipulator equipped with a visual positioning system, a plurality of battery cells having an initial temperature in step S2 are simultaneously grasped; during the grasping process, the manipulator continuously blows hot air toward the grasped battery cells through a hot air blowing port provided thereon to maintain or increase the temperature of the battery cells; guided by the visual positioning system, the grasped battery cells are precisely placed according to the preset array positions on the adhesive film in the molten adhesive state in step S1; the heat of the battery cells promotes rapid and firm adhesion between the battery cells and the molten adhesive film, thereby fixing the battery cells in position;

[0010] S4. Welding: Lay welding wires on the glass plate with the array swing pieces completed, connect the cells in the array in series, and perform laser welding to form a cell string of the photovoltaic module.

[0011] As a preferred technical solution of the present invention, the preparation process of the glass plate in step S1 specifically includes:

[0012] S101, receiving a glass plate through a transverse glass plate transmission line;

[0013] S102, transferring the glass sheet to a vertical glass sheet transmission line perpendicular to the horizontal transmission line;

[0014] S103, covering the upper surface of the glass plate with a film at the front end of the vertical transmission line, and simultaneously heating the bottom of the glass plate to 70-90° C. to melt the film;

[0015] S104, using a scraper to flatten the molten adhesive film to form a uniform adhesion layer.

[0016] As a preferred technical solution of the present invention, the cell preparation process in step S2 includes:

[0017] The finished battery cell is divided into several small-area battery cells by laser scribing;

[0018] Dry at 80-100°C for 3 to 10 seconds to bring the cell to an initial temperature of 40 to 60°C.

[0019] As a preferred technical solution of the present invention, in step S3:

[0020] The manipulator grabs 4 or 6 battery cells at the same time;

[0021] The temperature of the hot air outlet is set to 80°C and the wind speed is 0.5 to 2 m / s;

[0022] During the placement process of the battery cells, the surface temperature is maintained at 70°C to 80°C, and the bonding and curing time after contact with the film is ≤1.0 second.

[0023] As a preferred technical solution of the present invention, the visual positioning system in step S3 performs the following operations:

[0024] Identify the positioning marks at the four corners of the glass plate to establish a coordinate system;

[0025] Correct the battery cell grasping posture deviation in real time;

[0026] Control placement accuracy error ≤±0.2mm.

[0027] As a preferred technical solution of the present invention, the welding process of step S4 includes:

[0028] Synchronous operation through a double-station welding system;

[0029] Use wire drawing and wiring modules to lay multiple parallel welding wires on the cell array;

[0030] The spot length of laser welding is 10 to 40 mm and the width is 2 to 8 mm.

[0031] As a preferred technical solution of the present invention, the specific steps of the laser welding are:

[0032] The pressing mechanism is covered on the surface of the battery cell array where the welding wires have been laid, so that the parallel arranged heat conducting medium body can accurately press the corresponding welds of multiple parallel welding wires;

[0033] The long strip light spot is irradiated on the heat-conducting medium body, and the heat is conducted to the welding wire through the medium body to realize the melting connection.

[0034] The present invention also provides a photovoltaic module string welding processing equipment, comprising:

[0035] A glass carrier plate feeding mechanism is used to transport the glass plate with the molten adhesive film to the entrance of the string welding processing line;

[0036] Slicing and loading mechanism, used to provide battery cells with initial temperature;

[0037] The swing table and the swing robot are arranged at the front end of the string welding processing line, and are used to receive the battery cells from the scribing and loading mechanism. The swing robot is equipped with a visual positioning system, and its end effector is provided with a suction cup for grasping the battery cell and a hot air blowing port located relatively close to the middle of the suction cup. The swing robot is configured to grasp multiple battery cells at the same time. During the grasping process, hot air is continuously blown to the battery cells through the hot air blowing port to maintain or increase their temperature. The visual positioning system is used to guide the grasped multiple battery cells to be accurately placed according to the preset array position on the glass plate with molten adhesive film located on the swing table.

[0038] The gluing mechanism is used to provide a glue strip segment to the top of the glass plate where the battery cells are placed, and to adhere the glue strip segment to the battery cells;

[0039] The welding station is located after the gluing mechanism, and has wire drawing and routing modules at its front and rear ends for routing welding wires to connect the cells in the array and perform laser welding.

[0040] The unloading module and the unloading belt line are used to unload and output the welded photovoltaic modules.

[0041] As a preferred technical solution of the present invention, the glass supporting plate feeding mechanism includes a horizontal glass plate transmission line and a vertical glass plate transmission line; the horizontal glass plate transmission line is arranged parallel to the string welding processing line, and is used to transport the glass plate to the vertical glass plate transmission line, and the vertical glass plate transmission line is arranged perpendicular to the horizontal glass plate transmission line, and is used to transport the glass plate with a molten adhesive film to the entrance of the string welding processing line.

[0042] Furthermore, a film attaching device is provided at the front end of the vertical glass plate transmission line, which is used to cover the glass plate with film and heat the bottom of the glass plate to make the film melt and adhere. The film attaching device is also provided with a scraper for flattening the film.

[0043] The present invention according to the above scheme has the following beneficial effects:

[0044] The present invention integrates multiple operation links by using a disposable array of swing plates and direct welding on the glass plate. Only one main operation area is needed to complete the battery placement and welding process, which significantly reduces the equipment footprint and improves space utilization.

[0045] The present invention uses a robot to directly place the cell on the molten adhesive film before it is welded, avoiding the secondary handling operation of the welding position and effectively reducing the risk of damage to the welding position. In the one-time array placement step, the robot simultaneously grabs multiple cell slices and places them quickly and accurately, reducing the time consumed in placing a single cell. It also eliminates the secondary handling of the cell string and the waiting time for typesetting in the traditional process, making the production process more compact and efficient. At the same time, the application of laser welding technology also further accelerates the welding speed, significantly improving the overall production efficiency of photovoltaic modules.

[0046] In addition, the battery cells are sliced, divided and dried to reach their initial temperature, and hot air is continuously blown from the hot air outlet during the grabbing process to maintain or increase the temperature. When the battery cells in the high temperature state come into contact with the molten adhesive film, the molecular diffusion and cross-linking reaction between the two can be quickly promoted, thereby achieving fast and strong bonding, and improving the structural stability and reliability of the photovoltaic modules. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Figure 1 It is a structural schematic diagram of the present invention;

[0048] Figure 2 Flow chart of the process of the present invention;

[0049] Figure 3 Flowchart of steps for preparing glass sheets;

[0050] Figure 4 Flowchart of steps for preparing the cell;

[0051] Figure 5 This is a flow chart of the battery cell placement steps.

[0052] In the figure,

[0053] 1. Glass carrier plate feeding mechanism; 11. Horizontal glass plate transmission line; 12. Vertical glass plate transmission line; 13. Glass taking robot;

[0054] 2. Slicing and loading mechanism;

[0055] 3. Film swing table; 31. Film swing robot;

[0056] 4. Glue sticking mechanism;

[0057] 5. Welding station; 51. Wire drawing and wiring module;

[0058] 6. Unloading module; 61. Discharging conveyor line. DETAILED DESCRIPTION

[0059] To better understand the objectives, technical solutions, and technical effects of the present invention, the present invention is further explained below with reference to the accompanying drawings and embodiments. It should be noted that similar reference numerals and letters represent similar items in the following drawings. Therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings. It should also be noted that the embodiments described below are intended only to illustrate the present invention and are not intended to limit the present invention.

[0060] It should be noted that when an element is referred to as being "fixed on" or "disposed on" another element, it may be directly on the other element or there may also be an intermediate element; when an element is considered to be "connected to" another element, it may be directly connected to the other element or there may be an intermediate element at the same time.

[0061] The indicated orientation or positional relationship is based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of the application is typically placed when in use, or the orientation or positional relationship commonly understood by those skilled in the art, or the orientation or positional relationship in which the product of the application is typically placed when in use. This is for the purpose of facilitating the description of the present application and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation. Therefore, it should not be understood as limiting the present application. The term "plurality" means two or more, unless otherwise expressly and specifically limited.

[0062] like Figures 1 to 5 As shown, a photovoltaic module string welding process includes the following steps:

[0063] S1. Glass plate preparation and film treatment: providing a glass plate, covering the upper surface of the glass plate with a film, and heating the bottom of the glass plate to make the film in a molten and adhered state;

[0064] S2. Cell preparation: providing finished cell sheets coated with insulating adhesive, dicing the finished cell sheets into a number of smaller cells, and drying the cells during the dicing process so that the cells have an initial temperature;

[0065] S3, disposable array placement: Using a manipulator equipped with a visual positioning system, a plurality of battery cells having an initial temperature in step S2 are simultaneously grasped; during the grasping process, the manipulator continuously blows hot air toward the grasped battery cells through a hot air blowing port provided thereon to maintain or increase the temperature of the battery cells; guided by the visual positioning system, the grasped battery cells are precisely placed according to the preset array positions on the adhesive film in the molten adhesive state in step S1; the heat of the battery cells promotes rapid and firm adhesion between the battery cells and the molten adhesive film, thereby fixing the battery cells in position;

[0066] S4. Welding: Lay welding wires on the glass plate with the array swing pieces completed, connect the cells in the array in series, and perform laser welding to form a cell string of the photovoltaic module.

[0067] The process of this invention optimizes equipment space by integrating and innovating the placement and welding of the cells. During the glass plate preparation and film handling steps, the film is kept in a molten, adhered state, facilitating the subsequent direct placement and fixation of the cells. During the one-time array placement step, a robot is used to directly place the cells on the film, followed by direct welding. This eliminates the need to weld the cell strings in other areas before moving them for layout, as is done in traditional processes. This reduces the number of placement areas and welding stations, simplifies the equipment layout, and ultimately reduces the equipment footprint.

[0068] The present invention's process optimizes equipment space because conventional processes involve secondary handling of battery strings, external forces during robotic gripping, and vibration during movement, which can easily damage already welded locations. The present invention's process changes the order of operations, utilizing the adhesive film's melt-adhesive properties to secure the cells to the glass plate before welding. This avoids the need for handling the welding locations and eliminates the risk of damage at the root of the process.

[0069] The processing technology of the present invention realizes the improvement of production efficiency by the following principles: a one-time array placement link adopts a robot arm equipped with a visual positioning system to grab multiple battery cells at the same time, and realizes fast and accurate placement through the precise guidance of the visual positioning system, which saves a lot of time compared with the traditional piece-by-piece placement; at the same time, the secondary handling and typesetting waiting links of the battery string are eliminated, making the production process more coherent; laser welding technology has the characteristics of concentrated energy, fast welding speed, and small heat-affected zone, and can quickly complete the series welding of battery cells. Multiple technical means work together to effectively improve production efficiency.

[0070] Finally, the principle behind the enhanced bonding strength achieved by the present process lies in: during the cell preparation step, the cells are dried during the dicing and dicing process to reach their initial temperature. During the one-shot array placement, the robot continuously blows hot air from the hot air outlet to ensure that the cells are at a high temperature when in contact with the adhesive film. High temperatures accelerate the movement of molecules on the surfaces of the adhesive film and the cells, reducing the film's viscosity and promoting interpenetration and diffusion between the molecules, forming stronger intermolecular forces. This results in a fast and secure bond, enhancing the overall structural strength of the photovoltaic module.

[0071] In the present invention, the preparation process of the glass plate in step S1 specifically includes:

[0072] S101, receiving a glass sheet through a transverse glass sheet transmission line 11;

[0073] S102, transferring the glass sheet to a vertical glass sheet transmission line 12 perpendicular to the horizontal transmission line;

[0074] The horizontal and vertical glass plate conveyor lines 12 form an orderly conveying system. The horizontal glass plate conveyor line 11 is responsible for receiving glass plates and transporting them to the designated location. Through mechanical transmission or other transfer devices, the glass plates are accurately transferred to the vertical glass plate conveyor line 12 perpendicular to the horizontal conveyor line. The vertical cross-conveyor layout utilizes spatial position conversion to achieve a smooth transition of glass plates between different processes, allowing glass plates to enter the film coating, heating and melting, and scraping processes in the established processing sequence. This avoids the accumulation or misalignment of glass plates caused by chaotic conveyor paths, ensuring the consistency and efficiency of the production process.

[0075] S103. Covering the upper surface of the glass plate with an adhesive film at the front end of the vertical transmission line, and simultaneously heating the bottom of the glass plate to 50-120° C. to melt the adhesive film. This temperature range allows the adhesive film to reach an optimal melting state, reducing its viscosity and enhancing its fluidity and plasticity. In this state, the adhesive film can better fill the tiny concave and convex surfaces of the glass plate, achieving a tight fit.

[0076] S104, using a scraper to flatten the molten film to form a uniform adhesion layer, further eliminating stress and bubbles inside the film, increasing the contact area between the film and the glass plate, thereby improving the adhesion between the two and ensuring that the film is firmly attached to the glass plate.

[0077] It can be seen that the entire glass plate preparation process achieves improved processing accuracy through precisely designed transmission lines and standardized operating procedures. The refined control of the transmission process and processing operations makes the film treatment effect of each glass plate highly repeatable and consistent, thereby improving the overall accuracy of photovoltaic module processing.

[0078] In the present invention, the cell preparation process in step S2 includes:

[0079] The finished battery cell is divided into several small-area battery cells by laser scribing;

[0080] When the laser beam is focused onto the surface of the finished cell, the instantaneous high temperature causes the cell material to melt and vaporize rapidly, thus enabling cutting. Due to the concentrated energy of the laser beam and the small spot diameter, high-precision micro-processing is possible. During the cutting process, there is no need for direct contact with the cell, thus avoiding the stress and damage caused by friction between the blade and the cell during mechanical cutting, ensuring the integrity and electrical performance of the cell. Furthermore, the laser's rapid scanning characteristics enable it to complete the scribing of a large number of cells in a short period of time, significantly improving cutting efficiency.

[0081] Drying at 80°C for 3 to 10 seconds allows the cells to reach an initial temperature of 40°C to 60°C. Continuous blowing of hot air from the subsequent robotic hot air outlet maintains or increases the temperature, which can quickly promote molecular diffusion and cross-linking reactions between the cells and the molten film when they come into contact. Compared with the case without an initial temperature, the power required for the robotic hot air outlet can be greatly reduced, thereby reducing energy consumption. At the same time, the appropriate initial temperature and subsequent heating work together to allow the cells to be combined with the film at a more optimal high temperature state, effectively reducing bonding time, enhancing bonding strength, and improving the overall performance and stability of photovoltaic modules.

[0082] It can be seen that in step 2, the integrated operation process of laser scribing and drying treatment integrates the cell segmentation and temperature treatment links, avoiding the material transfer and waiting time between different equipment in the traditional process, making the production process more compact and efficient, reducing production stagnation caused by poor process connection, and improving the continuity and efficiency of the entire photovoltaic module production process.

[0083] In the present invention, in step S3:

[0084] The manipulator grabs 4 or 6 battery cells at the same time;

[0085] By grabbing multiple solar cells at a time, the number of times the robot goes back and forth to pick up the cells is reduced, and the non-productive time during the cell placement process is reduced; with the assistance of the visual positioning system, multiple solar cells can be placed in the preset position quickly and accurately at the same time, greatly improving the speed of cell array placement, thereby improving the production efficiency of the entire photovoltaic module string welding process.

[0086] The temperature of the hot air outlet is set to 80°C and the wind speed is 0.5 to 2 m / s;

[0087] During the placement process of the battery cells, the surface temperature is maintained at 70°C to 80°C, and the bonding and curing time after contact with the film is ≤1.0 second.

[0088] The 80°C hot air outlet temperature and 0.5 to 2m / s wind speed settings are based on accurate calculations of the temperature and heat transfer efficiency required for bonding the battery cell to the film. They can effectively transfer heat to the battery cell. The wind speed is controlled within this range, which can not only ensure that the hot air acts evenly on the surface of the battery cell and maintain the battery cell temperature in the ideal range of 70°C to 80°C, but also avoid excessive heat loss or unnecessary impact on the battery cell due to excessive wind speed. At a temperature of 50°C to 120°C, the film is in a good molten flow state, and the molecular activity on the surface of the battery cell is enhanced. When the two come into contact, the diffusion rate between the molecules is accelerated, and a cross-linking reaction can occur quickly in a short time of ≤1.0 second to form a strong bond, ensuring the bonding quality and structural stability of the photovoltaic module.

[0089] In the present invention, the visual positioning system in step S3 performs the following operations:

[0090] Identify the positioning marks at the four corners of the glass plate to establish a coordinate system;

[0091] Correct the battery cell grasping posture deviation in real time;

[0092] Control placement accuracy error ≤±0.2mm.

[0093] The visual positioning system uses image recognition technology, using cameras mounted on the robot or at specific locations on the production line, to detect and analyze the positioning marks on the four corners of the glass sheet. By calculating the coordinates of the marked points in the image, it establishes a coordinate system corresponding to the actual physical space. During the cell placement process, the system compares the preset cell position information with the actual image coordinates. Using a coordinate conversion algorithm, it precisely controls the robot's movement distance and direction, ensuring that the placement and position of each cell are within strict quality standards, with a cell placement accuracy error of ≤±0.2mm.

[0094] In the present invention, the welding process of step S4 includes:

[0095] The dual-station welding system operates synchronously; each station can independently complete the wire laying and laser welding operations. In actual production, the two stations can respectively weld different photovoltaic modules, achieving parallel processing and doubling the welding efficiency.

[0096] A wire drawing and wiring module 51 is used to lay multiple parallel welding wires on the battery cell array;

[0097] The wire drawing and routing module 51 is a mature existing technology, and can be referenced by the wire routing mechanism of a cell stringer developed earlier by our company (Patent Publication No. CN222776539U). The wire feeding assembly's loading rack, wire drawing device, and wire cutting device work together to automatically draw and cut the welding wire, increasing efficiency by over 50% compared to manual operation. The wire routing assembly's end clamping device and wire clamping and cutting knife combination can simultaneously clamp multiple welding wires and precisely adjust the spacing, ensuring parallel routing accuracy of ≤±0.1mm, meeting the wiring requirements of high-density cell arrays.

[0098] The laser welding spot length ranges from 10 to 40 mm, and the width ranges from 2 to 8 mm. The long, strip-shaped spot can simultaneously cover multiple parallel welds, allowing a single exposure to complete the fusion connection of multiple wires. For example, for 12 parallel welds spaced 5 to 20 mm apart, a traditional circular spot would require approximately 36 passes, while the long, strip-shaped spot can complete the process in just one or two scans. This improves welding efficiency by over 60%, reducing the welding time per component to just 8 to 12 seconds.

[0099] Laser welding is a mature existing technology. You can refer to a laser welding device developed earlier by our company (patent publication number CN116833562A). Specifically, the specific steps of laser welding are:

[0100] The pressing mechanism is covered on the surface of the battery cell array where the welding wires have been laid, so that the parallel arranged heat conducting medium body can accurately press the corresponding welds of multiple parallel welding wires;

[0101] The long strip light spot is irradiated on the heat-conducting medium body, and the heat is conducted to the welding wire through the medium body to realize the melting connection.

[0102] Laser energy is indirectly transferred to the welding wire through a thermally conductive medium, preventing localized overheating caused by direct laser exposure to the cell. The thermal conductivity of the thermally conductive medium (such as graphite or ceramic) concentrates the welding temperature at the interface between the welding wire and the cell (approximately 200-300°C), while the temperature rise in non-welding areas is less than 10°C. This reduces the cell fragmentation rate to less than 0.5%, and reduces electrical performance degradation by 0.15%.

[0103] Among them, the optical path system shapes the circular Gaussian beam emitted by the laser into a long strip through an optical path shaping module (such as a cylindrical mirror and an aperture). The spot length is adjusted by the focal length of the cylindrical mirror (the longer the focal length, the longer the spot), and the width is controlled by the beam divergence angle. The heat-conducting medium (thermal conductivity ≥ 200W / (m·K)) is tightly attached to the surface of the battery cell. When the laser beam irradiates the medium, the energy transfer path is: laser energy → absorption by the surface of the medium → heat conduction to the contact interface between the medium and the welding wire → melting of the welding wire → metallurgical bonding with the battery cell. This indirect heating mode concentrates the heat in the weld area, and the heat diffusion range is ≤0.5mm, avoiding thermal damage caused by direct laser irradiation to the battery cell. Taking the graphite medium as an example, its thermal diffusivity is 10 -5 m 2 / s, heat can be transferred to the welding wire within 5ms, achieving fast welding.

[0104] The present invention also provides a photovoltaic module string welding processing equipment, comprising:

[0105] The glass carrier plate feeding mechanism 1 is provided with a glass taking robot 13 for transferring the glass plate with the molten adhesive film to the entrance of the string welding processing line;

[0106] Slicing and loading mechanism 2, used to provide battery cells with an initial temperature;

[0107] The scribing and loading mechanism includes a scribing mechanism and a loading mechanism. The scribing mechanism, also known as a splitting mechanism, is a mature existing technology. Reference can be made to the notching and splitting mechanism of a battery processing device developed earlier by our company (Patent Publication No. CN218964397U). It involves two steps: first, laser scribing the center of the cell horizontally, and second, breaking the cell along the scribing line. The loading mechanism uses a robotic arm to transfer small-area cells to the placement table 3.

[0108] The swing table 3 and the swing robot 31 are arranged at the front end of the string welding processing line, and are used to receive the battery cells from the scribing and loading mechanism 2. The swing robot 31 is equipped with a visual positioning system, and its end effector is provided with a suction cup for grasping the battery cell and a hot air blowing port located relatively close to the middle of the suction cup. The swing robot 31 is configured to grasp multiple battery cells at the same time. During the grasping process, hot air is continuously blown to the battery cells through the hot air blowing port to maintain or increase their temperature. The visual positioning system is used to guide the grasped multiple battery cells to be accurately placed according to the preset array position on the glass plate with molten adhesive film located on the swing table 3.

[0109] The adhesive bonding mechanism 4 is used to provide adhesive strips to the top of the glass plate on which the battery cells are placed, and to bond the adhesive strips to the battery cells;

[0110] The welding station 5 is arranged behind the adhesive bonding mechanism 4. Wire drawing and routing modules 51 are provided at its front and rear ends for routing welding wires to connect the cells in the array and perform laser welding.

[0111] The unloading module 6 and the unloading belt line 61 are used to smoothly remove the welded photovoltaic components from the welding station 5 and transfer them to the unloading belt line 61 to realize the unloading and output of the components.

[0112] The glass carrier plate feeding mechanism 1 facilitates the transport, adhesive film application, and melt pretreatment of the glass plates, providing a uniformly adhered substrate for the cell swinging plates. The glass carrier plate feeding mechanism 1 comprises a transverse glass plate transmission line 11 and a vertical glass plate transmission line 12. The transverse glass plate transmission line 11 is arranged parallel to the string welding line and is used to transport glass plates to the vertical glass plate transmission line 12. The vertical glass plate transmission line 12 is arranged perpendicular to the transverse glass plate transmission line 11 and is used to transport glass plates with molten adhesive films attached to the string welding line entrance.

[0113] The front end of the vertical glass plate transmission line 12 is provided with a film attaching device, which is used to cover the glass plate with a film and heat the bottom of the glass plate to melt and adhere the film. The film attaching device is also provided with a scraper for flattening the film.

[0114] In a specific embodiment, the horizontal glass plate transmission line 11 uses a metal mesh belt or a vacuum adsorption conveyor belt, equipped with a servo motor drive, and photoelectric sensors are installed on both sides to detect the position of the glass plate. The horizontal glass plate transmission line 11 receives the upstream incoming glass plate along the direction parallel to the string welding processing line (X axis), and realizes the horizontal alignment of the glass plate by positioning the baffle and the cylinder push block. The vertical glass plate transmission line 12 is perpendicular to the horizontal transmission line (Y axis), uses a ball screw + linear guide module, and is equipped with a vacuum adsorption platform, which can carry large-sized glass plates. The vertical glass plate transmission line 12 transfers the horizontally transmitted glass plate to the vertical line through a 90° steering mechanism, and transports it to the string welding entrance along the negative direction of the Y axis. The film reel of the film attaching device is installed at the front end of the vertical transmission line, and the tension control mechanism ensures that the film is unfolded flatly; the heating unit of the film attaching device adopts an infrared heating plate, with a heating temperature of 50℃ to 120℃ and a heating time of 10-20 seconds to melt the film; the elastic metal scraper of the film attaching device moves horizontally to scrape the film flat, with a scraper pressure of 5-10N / cm, ensuring that the film thickness uniformity error is ≤±5μm and eliminating bubbles and wrinkles.

[0115] In a specific embodiment, the swing table 3 includes a supporting platform with a constant temperature heating plate embedded in the platform. The mechanical body of the swing manipulator 31 can be a 6-axis industrial robot to meet the needs of grabbing 4-6 battery cells at the same time. The end effector of the swing manipulator 31 is provided with a suction cup array, and the suction cup array is configured as a plurality of suction cup nozzles for sucking a battery cell; the end effector of the swing manipulator 31 is also provided with a plurality of hot air outlets located in the center of the plurality of suction cup nozzles. The wind speed of the hot air outlet is adjustable and the temperature is 80°C, ensuring that the surface temperature of the battery cell is maintained at 70-80°C during the placement process.

[0116] The visual positioning system on the wafer table 3, consisting of a 2D vision camera and laser displacement sensor, is installed above the wafer manipulator 31. The algorithm follows these steps: The positioning marks on the four corners of the glass plate are identified, and a world coordinate system is established using a perspective transformation algorithm. Images of the captured cells are captured in real time, and the rotation angle and offset are calculated. Fine-tuning of the end effector is driven by an inverse solution of the robot's kinematics. Based on the preset array coordinates, an optimal wafer trajectory is generated to prevent collisions between the suction cup and the positioned cells.

[0117] After the swing robot 31 grabs the battery cell from the dicing mechanism, the hot air outlet is started simultaneously to maintain the temperature of the battery cell during the movement; after reaching the top of the swing table 3, the visual system compensates for the positioning error in real time to ensure the accuracy of the swing position.

[0118] In a specific embodiment, the gluing mechanism 4 adopts a battery cell gluing device disclosed in patent publication number CN222897491U, and the installation position is located between the swing table 3 and the welding station 5 of the device of the present invention. The installation direction ensures that the glue strip segment output by the gluing mechanism 4 can accurately cover the gap or edge position of the battery cell array and fit tightly with the upper surface of the battery cell.

[0119] In an optional embodiment, the gripping mechanism of unloading module 6 utilizes a vacuum-assisted robotic arm or pneumatic gripper, driven by air pressure to grasp the modules. Three-dimensional motion is achieved through linear guides or a multi-axis robotic arm, coupled with a servo motor drive to ensure a smooth unloading process. The unloading conveyor 61 receives the photovoltaic modules transferred by unloading module 6 and transports them in a fixed direction to subsequent processes (such as lamination and EL testing) or to a temporary storage area for finished products, achieving continuous module output.

[0120] The technical features of the above embodiments can be combined arbitrarily. To make the description concise, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0121] The above embodiments merely illustrate several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent. It should be noted that a person skilled in the art would be able to make various modifications and improvements without departing from the spirit of the present invention, all of which fall within the scope of protection of the present invention. Therefore, the scope of protection of the patent for this invention shall be determined by the appended claims.

Claims

1. A photovoltaic module string welding process, characterized in that: The following steps are involved: S1. Glass plate preparation and film treatment: providing a glass plate, covering the upper surface of the glass plate with a film, and heating the bottom of the glass plate to make the film in a molten and adhered state; S2. Cell preparation: providing finished cell sheets coated with insulating adhesive, dicing the finished cell sheets into a number of smaller cells, and drying the cells during the dicing process so that the cells have an initial temperature; S3, disposable array placement: Using a manipulator equipped with a visual positioning system, a plurality of battery cells having an initial temperature in step S2 are simultaneously grasped; during the grasping process, the manipulator continuously blows hot air toward the grasped battery cells through a hot air blowing port provided thereon to maintain or increase the temperature of the battery cells; guided by the visual positioning system, the grasped battery cells are precisely placed according to the preset array positions on the adhesive film in the molten adhesive state in step S1; the heat of the battery cells promotes rapid and firm adhesion between the battery cells and the molten adhesive film, thereby fixing the battery cells in position; S4. Welding: Lay welding wires on the glass plate with the array swing pieces completed, connect the cells in the array in series, and perform laser welding to form a cell string of the photovoltaic module.

2. The photovoltaic module string welding process according to claim 1, characterized in that: The preparation process of the glass plate in step S1 specifically includes: S101, receiving a glass plate through a transverse glass plate transmission line; S102, transferring the glass sheet to a vertical glass sheet transmission line perpendicular to the horizontal transmission line; S103, covering the upper surface of the glass plate with a film at the front end of the vertical transmission line, and simultaneously heating the bottom of the glass plate to 70-90° C. to melt the film; S104, using a scraper to flatten the molten adhesive film to form a uniform adhesion layer.

3. The photovoltaic module string welding process according to claim 1, characterized in that: The cell preparation process in step S2 includes: The finished battery cell is divided into several small-area battery cells by laser scribing; Dry at 80-100°C for 3 to 10 seconds to bring the cell to an initial temperature of 40 to 60°C.

4. The photovoltaic module string welding process according to claim 1, characterized in that: In the step S3: The manipulator grabs 4 or 6 battery cells at the same time; The temperature of the hot air outlet is set to 80°C and the wind speed is 0.5 to 2 m / s; During the placement process of the battery cells, the surface temperature is maintained at 70°C to 80°C, and the bonding and curing time after contact with the film is ≤1.0 second.

5. The photovoltaic module string welding process according to claim 1, characterized in that: The visual positioning system in step S3 performs the following operations: Identify the positioning marks at the four corners of the glass plate to establish a coordinate system; Correct the battery cell grasping posture deviation in real time; Control placement accuracy error ≤±0.2mm.

6. The photovoltaic module string welding process according to claim 1, characterized in that: The welding process of step S4 includes: Synchronous operation through a double-station welding system; Use wire drawing and wiring modules to lay multiple parallel welding wires on the cell array; The spot length of laser welding is 10 to 40 mm and the width is 2 to 8 mm.

7. The photovoltaic module string welding process according to claim 1 or 6, characterized in that: The specific steps of the laser welding are: The pressing mechanism is covered on the surface of the battery cell array where the welding wires have been laid, so that the parallel arranged heat conducting medium body can accurately press the corresponding welds of multiple parallel welding wires; The long strip light spot is irradiated on the heat-conducting medium body, and the heat is conducted to the welding wire through the medium body to realize the melting connection.

8. A photovoltaic module string welding processing equipment, characterized in that: include: A glass carrier plate feeding mechanism is used to transport the glass plate with the molten adhesive film to the entrance of the string welding processing line; Slicing and loading mechanism, used to provide battery cells with initial temperature; The swing table and the swing robot are arranged at the front end of the string welding processing line, and are used to receive the battery cells from the scribing and loading mechanism. The swing robot is equipped with a visual positioning system, and its end effector is provided with a suction cup for grasping the battery cell and a hot air blowing port located relatively close to the middle of the suction cup. The swing robot is configured to grasp multiple battery cells at the same time. During the grasping process, hot air is continuously blown to the battery cells through the hot air blowing port to maintain or increase their temperature. The visual positioning system is used to guide the grasped multiple battery cells to be accurately placed according to the preset array position on the glass plate with molten adhesive film located on the swing table. The gluing mechanism is used to provide a glue strip segment to the top of the glass plate where the battery cells are placed, and to adhere the glue strip segment to the battery cells; The welding station is located after the gluing mechanism, and has wire drawing and routing modules at its front and rear ends for routing welding wires to connect the cells in the array and perform laser welding. The unloading module and the unloading belt line are used to unload and output the welded photovoltaic modules.

9. The photovoltaic module string welding processing equipment according to claim 8, characterized in that: The glass carrier plate feeding mechanism includes a horizontal glass plate transmission line and a vertical glass plate transmission line; the horizontal glass plate transmission line is arranged parallel to the string welding processing line, and is used to transport the glass plate to the vertical glass plate transmission line; the vertical glass plate transmission line is arranged perpendicular to the horizontal glass plate transmission line, and is used to transport the glass plate with a molten adhesive film to the entrance of the string welding processing line.

10. The photovoltaic module string welding processing equipment according to claim 9, characterized in that: The front end of the vertical glass plate transmission line is provided with a film attaching device, which is used to cover the glass plate with film and heat the bottom of the glass plate to make the film melt and adhere. The film attaching device is also provided with a scraper for flattening the film.

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