Novel device and method for intelligently disassembling waste photovoltaic silicon cell panel

Abstract

The invention discloses a novel device and method for intelligently disassembling a waste photovoltaic silicon cell panel. The device comprises two layers of transmission rollers and a conveying belt penetrating through the two layers of transmission rollers. The main control board is integrated with a fuzzy controller and a PID (Proportion Integration Differentiation) controller, a hierarchical decision algorithm and a BP (Back Propagation) neural network are deployed on the main control board, the PID controller is connected with the fuzzy controller, and the BP neural network is used for dynamically adjusting PID parameters of the PID controller; the support is fixedly provided with a six-axis servo motor, a back plate collecting bin, an air cooling fan and a copper solder strip absorbing device, the six-axis servo motor is fixedly connected with a vacuum suction cup array, the air cooling fan is fixedly provided with an infrared imager, and the support is provided with a double-layer heat cutter head. A resistance heating module and an electromagnetic induction heating module are nested on the outer surface of the double-layer hot cutter head, and a pressure sensor, a laser sensor and a temperature sensor which are fixedly connected with the main control board are fixedly arranged on the outer surface of the double-layer hot cutter head. According to the invention, the waste photovoltaic silicon cell panel can be intelligently and accurately segmented, the dependence on manpower is reduced, and high-quality recovery of the silicon cell panel is realized.

Description

Technical Field

[0001] The present invention belongs to the technical field of waste photovoltaic component recycling, and specifically relates to a novel intelligent device and method for disassembling waste photovoltaic silicon battery panels. Background Art

[0002] With the continuous growth of global demand for clean energy, the photovoltaic industry has developed rapidly in recent years. Since the beginning of the 21st century, the annual growth rate of my country's silicon solar panel production has exceeded 100%, and sales have continued to rise. It is expected that the peak of silicon panel scrapping will be in 2030. Therefore, how to efficiently recycle silicon solar panels has become crucial.

[0003] Existing silicon solar panel recycling methods primarily include physical, chemical, and thermal methods. Physical methods can leave adhesive residue, chemical methods can cause secondary contamination, and traditional thermal methods are highly susceptible to damage to silicon wafers. While hot knife technology, based on traditional thermal treatment methods, can reduce thermal damage through localized heating, it relies on manual control of temperature, pressure, and disassembly paths, resulting in low separation accuracy, poor adaptability, and limited intelligence.

[0004] Therefore, the development of a hot knife device focusing on intelligent disassembly and adaptive control has positive significance for the recycling of waste silicon solar panels. Summary of the Invention

[0005] The purpose of the present invention is to provide a new intelligent device and method for disassembling waste photovoltaic silicon solar panels, which can intelligently and accurately divide waste photovoltaic silicon solar panels, reduce dependence on manual experience, and reduce damage to silicon solar cells, thereby achieving high-quality recycling of silicon solar panels.

[0006] The present invention is achieved through the following technical solutions:

[0007] A novel intelligent device for dismantling waste photovoltaic silicon panels includes a control system, a conveyor belt, drive rollers, and a bracket. The drive rollers are provided in two layers. The conveyor belt runs between the two layers of drive rollers, and a gap is left between the conveyor belt and the upper layer of drive rollers for the waste photovoltaic silicon panels to pass through. The gap between the starting end of the upper layer of drive rollers and the conveyor belt constitutes a feed port, and the gap between the tail end of the upper layer of drive rollers and the tail end of the conveyor belt constitutes a discharge port.

[0008] The control system is a main control board that integrates a fuzzy controller and a PID controller. The main control board is deployed with a hierarchical decision algorithm and a BP neural network. The PID controller and the fuzzy controller are connected, and the BP neural network is used to dynamically adjust the PID parameters of the PID controller.

[0009] A six-axis servo motor is fixedly installed on the top of the bracket, and the end effector of the six-axis servo motor is fixedly connected to a vacuum suction cup array. A backplane collection bin, an air-cooling fan, and a copper welding strip absorption device are fixedly installed at the tail end of the bracket, and the air outlet of the air-cooling fan is opposite to the inlet position of the copper welding strip absorption device. An infrared imager is fixedly installed at the air outlet of the air-cooling fan;

[0010] The bracket is provided with a double-layer hot knife head, and the outer surface of the double-layer hot knife head is embedded with a resistance heating module and an electromagnetic induction heating module, wherein: the electromagnetic induction heating module is connected to the PID controller and is connected to an external DC power supply through a high-frequency inverter; the resistance heating module is respectively connected to the PID controller and the output end of the voltage regulator, and the input end of the voltage regulator is connected to the DC power supply;

[0011] The double-layer hot knife head is fixedly installed with a pressure sensor, a laser sensor and a temperature sensor. The pressure sensor, the laser sensor, the temperature sensor and the infrared imager are all connected to the main control board. The real-time data collected by the pressure sensor, the laser sensor, the temperature sensor and the infrared imager is used as the input of the hierarchical decision algorithm, and the main control board uses the output of the hierarchical decision algorithm as the control signal.

[0012] Furthermore, ceramic heat insulation plates are fixedly installed on both sides of the bracket, and the transmission roller, conveyor belt and double-layer hot knife head are all located between a pair of ceramic heat insulation plates.

[0013] Furthermore, the transmission roller includes a mounting frame and a plurality of evenly distributed rollers rotatably connected to the mounting frame, wherein a pressure sensor is installed under the mounting frame of the upper transmission roller, and a ball screw is installed at the front and rear ends thereof, and the ball screw is connected to the stepping motor;

[0014] The pressure sensor and the stepper motor are both connected to the main control board.

[0015] Furthermore, a flow sensor is fixedly installed at the air outlet of the air-cooling fan, and the flow sensor is connected to the main control board.

[0016] Furthermore, the flow sensor, laser sensor, temperature sensor and pressure sensor are all connected to the main control board via the CAN FD bus protocol.

[0017] Furthermore, the electromagnetic induction heating module is a copper alloy coil spirally wound on the outer surface of the blade of the double-layer hot blade;

[0018] The resistance heating module is a nickel-chromium alloy wire array embedded in the cutter head, and the nickel-chromium alloy wire array and the copper alloy coil are staggered.

[0019] Furthermore, it also includes a touch screen, which is connected to the main control board.

[0020] Furthermore, a height-adjustable support foot is fixedly mounted on the bottom of the bracket, and a shock-absorbing rubber pad is fixedly mounted on the bottom of the support foot.

[0021] Furthermore, the surface of the double-layer hot knife head is coated with a boron nitride-based composite insulation layer.

[0022] A novel intelligent method for dismantling waste photovoltaic silicon panels comprises the following steps:

[0023] Step 1: The waste photovoltaic silicon panels with frames and aluminum boxes removed are transferred to the conveyor belt. The waste photovoltaic silicon panels enter the feed port, are firmly clamped by two layers of transmission rollers, and are continuously conveyed forward by the conveyor belt.

[0024] Step 2: Preheat the double-layer hot knife head to 200-300°C using the resistance heating module and the electromagnetic induction heating module. The double-layer hot knife head is slowly advanced along the laminated interface of the photovoltaic silicon solar cell at a set advancement speed to soften the EVA film and separate the glass and backplane from the silicon solar cell. At the same time, the double-layer hot knife head contacts the copper soldering tape and locally heats it for 5-10 seconds to soften the connection between the copper soldering tape and the silicon solar cell, thereby separating the copper soldering tape from the silicon solar cell.

[0025] During the cutting process, temperature sensors, laser sensors, and pressure sensors collect data on the temperature, position coordinates, and pressure of the double-layer hot cutter head and upload it to the main control board. A hierarchical decision-making algorithm deployed on the main control board uses temperature, coordinate, and pressure data as input to monitor the temperature, propulsion speed, and pressure of the double-layer hot cutter head in real time.

[0026] Fuzzy PID control is used to dynamically adjust the magnetic field frequency fem of the electromagnetic induction heating module, the resistance wire current density Jres of the resistance heating module, and the power ratio of the resistance heating module and the electromagnetic induction heating module, so as to control the temperature of the double-layer hot cutter head at 200-300℃, and make the axial and radial gradients ≤±3℃. The specific process is as follows: the temperature sensor collects the temperature data distributed on the cutter head in real time and inputs it into the fuzzy PID controller, combining the temperature error e(t), the temperature change rate Δe / Δt and the temperature gradient Fuzzy reasoning is performed to dynamically optimize PID parameters and output control instructions. Among them, the high-frequency inverter controls fem at 50kHz~100kHz according to the output of fuzzy PID. When fem>80kHz, the surface of the tool head is focused on for rapid heating to reduce the depth of heat penetration; when fem<60kHz, deep heating is enhanced to balance the axial and radial temperature gradients; the voltage regulator dynamically changes the output voltage according to the output of fuzzy PID and adjusts the current density Jres of the resistance heating module. When 30 <Jres≤50A / mm 2 , quickly compensate for low temperature areas, suppress radial and lateral gradients, when 10≤Jres≤30A / mm2 When heating, the steady-state temperature is maintained and energy consumption is reduced; by adjusting fem and Jres, the power ratio of the resistance heating module and the electromagnetic induction heating module is adjusted. In the low temperature range of 200-250℃, the ratio of the power Pres of the resistance heating module to the power Pem of the electromagnetic induction heating module is not less than 7:3, and the thermal inertia of the resistance heating module is used to compensate for temperature fluctuations; in the high temperature range of 250-300℃, the ratio of the power Pem of the electromagnetic induction heating module to the power Pres of the resistance heating module is not less than 6:4, and thermal hysteresis is reduced by a high-frequency magnetic field;

[0027] The layered decision algorithm dynamically adjusts the propulsion speed of the double-layer hot knife head according to the position coordinates of the double-layer hot knife head, and controls the pressure on the photovoltaic silicon battery panel to be between 0.5-2N.

[0028] Step 3: The main control board controls the six-axis servo robotic arm to drive the vacuum suction cup array to move to the glass and absorb the glass. Then, the six-axis servo robotic arm drives the vacuum suction cup array to transfer the glass to the glass collection bin.

[0029] Step 4: After the backboard is transported to the discharge port by the conveyor belt, it falls into the backboard collection bin under the action of gravity;

[0030] Step 5: The copper soldering tape attached to the silicon solar cell panel is conveyed forward by the conveyor belt. The air-cooling fan is started. The high-speed fan generates forced convection dry air to quickly reduce the temperature of the silicon solar cell panel. Under the blowing of the airflow, the softened copper soldering tape is completely peeled off from the surface of the silicon solar cell. The copper soldering tape is blown into the copper soldering tape absorption device located opposite the air-cooling fan.

[0031] During the purge process, the main control board monitors the surface temperature of the silicon cell using an infrared imager until its surface temperature is completely cooled to normal temperature and then transported to the next process.

[0032] The present invention has the following beneficial technical effects:

[0033] First, through fuzzy PID precise temperature control and local heating of each layer of high-efficiency waste photovoltaic silicon solar panels, the recovery rate and purity of silicon solar cells, glass, backplane and copper welding tape are improved, and the damage to silicon solar cells is reduced, reducing the loss and cost of the disassembly process; second, through low-temperature hot knife separation, the harmful gases produced by high-temperature decomposition are reduced, reducing the impact on the environment; third, through the main control board integrated with the hierarchical decision-making algorithm, the whole process intelligent operation is realized, improving production efficiency and safety; fourth, through cooling technology, the integrity of the silicon wafer is further protected, and high-quality recycling of materials is achieved; fifth, through the real-time capture of position coordinates by laser sensors, the advancement speed of the hot knife is dynamically adjusted, and the cutting quality is improved; sixth, according to the data collected by the pressure sensor, the transmission is optimized The contact pressure between the roller and the photovoltaic silicon solar panel, as well as the contact pressure between the hot knife and the photovoltaic silicon solar panel, realizes non-destructive separation with millimeter-level precision; seventh, through the data uploaded by the infrared imager and the flow sensor, the cooling parameters are adjusted in real time, realizing the effective separation of the copper-tin soldering tape and the silicon solar cell and the precise cooling of the silicon solar cell; in short, the present invention deploys a variety of sensors and introduces a hierarchical decision-making algorithm and fuzzy PID control to dynamically adjust various parameters, breaking through the traditional hot knife separation technology's reliance on manual experience, realizing intelligent non-destructive segmentation with millimeter-level precision, solving the core problems of traditional hot knife separation technology such as large temperature fluctuations, inaccurate recognition and poor compatibility, achieving the goals of silicon cell recovery rate ≥98% and waste gas emission reduction by 90%, and promoting the transformation of photovoltaic recycling to high efficiency, environmental protection and intelligence. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is a schematic diagram of the overall structure of the invention;

[0035] Figure 2 It is a partial cross-sectional structural schematic diagram of the invention;

[0036] Figure 3 It is a working principle diagram of the control system of the present invention;

[0037] Figure 4 It is a structural diagram of BP neural network;

[0038] Figure 5 It is the working flow chart of the control system of the present invention.

[0039] In the figure: 1. Feed port; 2. Conveyor belt; 3. Drive roller; 4. Vacuum suction cup array; 5. Double-layer hot knife head; 6. Pressure sensor; 7. Laser sensor; 8. Temperature sensor; 9. Back plate collection bin; 10. Air-cooling fan; 11. Copper welding strip absorption device; 12. Glass collection bin; 13. Ceramic insulation board; 14. Bracket; 15. Infrared imager; 16. Discharge port. DETAILED DESCRIPTION

[0040] The present invention will be further described in detail below with reference to specific embodiments, which are intended to explain the present invention rather than to limit it.

[0041] refer to Figure 1 and Figure 2 As shown, the present invention provides a novel intelligent device for disassembling waste photovoltaic silicon battery panels, comprising a bracket 14, a control system, a touch screen and two layers of transmission rollers 3, the two layers of transmission rollers 3 are located below the bracket 14, a conveyor belt 2 is provided between the two layers of transmission rollers 3, the transmission rollers 3 and the conveyor belt 2 are driven by a servo motor to achieve precise transmission, a gap is left between the upper transmission roller 3 and the conveyor belt 2 for the waste photovoltaic silicon battery panels to pass through, the gap between the starting end of the upper transmission roller 3 and the conveyor belt 2 constitutes a feed port 1, and the gap between the tail end of the upper transmission roller 3 and the conveyor belt 2 constitutes a discharge port 16, the waste photovoltaic silicon battery panels are transported to the feed port 1 by the conveyor belt 2, and are clamped and transported forward by the upper and lower transmission rollers 3, and the waste photovoltaic silicon battery panels on the conveyor belt 2 are firmly pressed by the transmission rollers 3, so that they are more stable during the subsequent cutting process, thereby preventing inaccurate cutting or equipment damage caused by displacement;

[0042] like Figure 3 As shown, the control system is a main control board integrated with a fuzzy controller and a PID controller, the main control board is connected to the touch screen, and the main control board is deployed with a hierarchical decision algorithm and Figure 4 The BP neural network shown in the figure dynamically adjusts the PID parameters according to the current error and historical status, optimizes the control effect of the PID controller, and combines the PID controller with the fuzzy controller to form fuzzy PID control, thereby achieving more accurate control;

[0043] like Figure 5 As shown in the figure, the real-time data collected by different sensors are de-noised by Kalman filtering and aligned with the timestamps before being used as the input of the hierarchical decision-making algorithm. The hierarchical decision-making algorithm includes a bottom real-time control layer and an upper intelligent decision-making layer. Among them, the bottom layer uses an adaptive fuzzy PID algorithm to adjust the temperature and position coordinate transformation of the double-layer hot knife head, and synchronously adjusts the conveying speed of the conveyor belt 2 and the fan speed of the air-cooling fan 10; the upper intelligent decision-making layer uses a lightweight convolutional neural network MobileNet-V3 to identify the type of waste photovoltaic silicon panels and call pre-stored process parameters. At the same time, the upper intelligent decision-making layer can combine with the Drools rule engine to diagnose abnormal signals, trigger graded alarms, and judge the integrity of waste photovoltaic silicon panels; the main control board controls the actuators of the device according to the output of the hierarchical decision-making algorithm, intelligently disassembles the waste photovoltaic silicon panels, and realizes automatic closed-loop control;

[0044] like Figure 1 and Figure 2As shown, the bracket 14 is provided with a double-layer hot knife head 5, and the outer surface of the double-layer hot knife head 5 is embedded with a resistance heating module and an electromagnetic induction heating module, wherein: the electromagnetic induction heating module is a high-purity copper alloy coil spirally wound on the surface of the knife head, the electromagnetic induction heating module is connected to the PID controller, and the electromagnetic induction heating module is connected to an external DC power supply through a high-frequency inverter, thereby generating an alternating magnetic field with a frequency of 50-100kHz, generating induced eddy currents in the metal matrix of the knife head, and generating instantaneous Joule heat; the resistance heating module is composed of a nickel-chromium alloy wire array embedded in the inside of the knife head, and is spatially staggered with the electromagnetic induction coil. The resistance heating module and the PID controller are connected. The controller is connected, and the resistance heating module is connected to the output end of the voltage regulator, and the input end of the voltage regulator is connected to a DC power supply. The fuzzy controller dynamically adjusts the magnetic field frequency of the electromagnetic induction heating module and the resistance wire current density of the resistance heating module through the PID controller based on the fuzzy rule base by compensating for nonlinear disturbances, effectively suppressing local overheating and improving the uniformity of temperature control; at the same time, the power ratio of the resistance heating module and the electromagnetic induction heating module is dynamically adjusted. Specifically, in the temperature range of 200-250°C, resistance heating is mainly used to ensure thermal inertia compensation, and in the temperature range of 250-300°C, electromagnetic induction heating is dominant to reduce thermal hysteresis;

[0045] The double-layer hot cutter head 5 adopts electromagnetic induction heating and resistance heating. Under the dual-mode heating synergy, the axial and radial temperature gradients of the cutter head are ≤±3°C. The thermocouple array embedded in the cutter head surface is used to feed back temperature data to the PID controller in real time. The PID controller combines the fuzzy logic algorithm to dynamically optimize the magnetic field frequency and the resistance wire current density. The current density can be adjusted within the range of 10-50A / mm. 2 , the magnetic field frequency is controlled at 50kHz~100kHz, and the dual-mode heating is adopted compared with the single resistance heating, which increases the heating efficiency to more than 30%;

[0046] like Figure 1 and Figure 2As shown, a pressure sensor 6 is fixedly installed at the bottom of the knife seat of the double-layer hot knife head 5, and laser sensors 7 are fixedly installed on the two layers of the double-layer hot knife head 5 respectively. A temperature sensor 8 is embedded in the surface of the double-layer hot knife head 5. The pressure sensor 6, the laser sensor 7 and the temperature sensor 8 are all connected to the control system. When the waste photovoltaic silicon battery panel is transported to the vicinity of the double-layer hot knife head 5 by the conveyor belt 2, the lamination interface of the waste photovoltaic silicon battery panel is located by the laser sensor 7, and the data is uploaded to the control system. The control system adjusts the knife head of the double-layer hot knife head 5 to align with the lamination interface of the photovoltaic silicon battery panel, and advances forward to cut the waste photovoltaic silicon battery panel, so that the EVA film is softened. , separating the glass and back sheet from the silicon cell. During the cutting process, the control system monitors the temperature, propulsion speed and force of the double-layer hot knife head in real time through the data fed back by the temperature sensor 8, laser sensor 7 and pressure sensor 6, and automatically adjusts the operating parameters. The control system can also upload the data to the touch screen for the operator to view in real time and make human intervention in time to make the cutting more accurate and stable. At the same time, the position of the copper welding strip is located with the help of the laser sensor 7, so as to accurately control the contact between the blade head of the double-layer hot knife head 5 and the copper welding strip, and locally heat it for 5 to 10 seconds to soften the connection between the copper welding strip and the silicon cell, and separate the copper welding strip from the silicon cell.

[0047] A glass collecting bin 12 is fixedly mounted on the inner side of the bracket 14, and a six-axis servo robotic arm connected to the control system is fixedly mounted on the top of the bracket 14. The base of the six-axis servo robotic arm is fixedly connected to the bracket 14 by high-strength bolts, and the end effector of the six-axis servo robotic arm is fixedly connected to the vacuum suction cup array 4. The vacuum suction cup array 4 is composed of a plurality of vacuum flexible silicone suction cups. The plurality of silicone suction cups are evenly distributed at set intervals, and the adsorption force is more uniform, which can prevent the glass from being deformed or damaged due to uneven local adsorption force. The adsorption surface of the flexible silicone suction cup is evenly distributed with micropores to enhance the adsorption force, so that it can fit tightly to the glass surface, making the adsorption more stable and reliable. When the glass is adsorbed, the six-axis servo robotic arm is controlled by the control system. The six-axis servo robotic arm transfers the glass smoothly to the glass collecting bin 12 with a positioning accuracy of ±0.1mm. The multi-joint collaborative control technology of the six-axis servo robotic arm can effectively suppress inertial vibration and can prevent the glass from being offset or broken during high-speed transportation.

[0048] The tail end of the bracket 14 is fixedly mounted with a backboard collection bin 9, an air-cooling fan 10 and a copper welding strip absorption device 11, wherein: the backboard collection bin 9 is located below the discharge port 16, and the separated backboard is transported to the discharge port 16 by the conveyor belt 2, and then falls into the backboard collection bin 9 under the action of gravity; the air outlet of the air-cooling fan 10 is directly opposite to the inlet of the copper welding strip absorption device 11, and the air outlet of the air-cooling fan 10 is provided with an infrared imager 15 for measuring the surface temperature of the silicon cell and a flow sensor for measuring the air flow at the air outlet of the air-cooling fan 10, and the infrared imager 15 and the flow sensor are both connected to the control system. The control system adjusts the wind speed of the air-cooling fan 10 in real time according to the temperature signal uploaded by the infrared imager 15 and the cold air flow rate uploaded by the flow sensor, and cools the silicon solar cell and the copper soldering tape at a cooling rate of 10°C / s-20°C / s, so that the copper soldering tape is completely peeled off from the silicon solar cell. Under the blowing of the airflow, the copper soldering tape absorption device 11 located opposite the air-cooling fan 10 absorbs the copper soldering tape swept by the air and stores it, realizing the separation of the copper soldering tape from the silicon solar cell. The temperature of the silicon solar cell is monitored in real time by the infrared imager 15. When its temperature drops to normal temperature, it is transmitted to the subsequent process.

[0049] The bracket 14 is fixedly mounted with a group of ceramic insulation boards 13. The drive roller 3, the conveyor belt 2 and the double-layer hot knife head 5 are all located between the group of ceramic insulation boards 13. The ceramic insulation boards 13 are made of ceramic materials with low thermal conductivity, which can effectively block heat from being transferred to the outside, maintain temperature stability, reduce heat loss, and at the same time provide additional mechanical protection for the components located therein.

[0050] Preferably, the conveyor belt 2 is made of a high-strength and high-temperature resistant composite material, and the surface is provided with anti-slip convex textures to enhance friction and prevent the silicon solar panels from twisting or sliding during transportation.

[0051] Preferably, the width of the conveyor belt 2 can be adjusted according to actual needs to be suitable for waste photovoltaic silicon panels of different sizes, thereby improving the versatility and flexibility of the equipment.

[0052] Preferably, the transmission roller 3 is made of high-strength aluminum alloy, and the surface is hardened, which not only ensures the stability of transmission but also extends the service life.

[0053] Preferably, the transmission roller 3 includes a mounting frame and a plurality of evenly distributed rollers rotatably connected to the mounting frame, ball screws are respectively installed at the front and rear ends of the mounting frame, and a pressure sensor 6 is installed on the mounting frame. The pressure sensor 6 is connected to the control system. The pressure distribution in the contact area between the photovoltaic silicon panel and the transmission roller is monitored in real time through the pressure sensor 6. The data is analyzed in combination with the elastic mechanics equation, and real-time data analysis is performed on the main control board. The optimal spacing between the two layers of transmission rollers 3 is dynamically calculated, and the ball screw is driven to move by a stepper motor to automatically adjust the vertical position of the upper transmission roller 3 to optimize the spacing between the two layers of transmission rollers 3, thereby achieving precise control of the pressure of the photovoltaic panel and making the transmission smoother.

[0054] Preferably, the bracket 14 is a high-strength steel frame structure, which has high strength to withstand dynamic loads, is corrosion-resistant, and adapts to different installation environments. It is used to support the weight of the entire device, making its operation stable and safe.

[0055] Preferably, the bottom of the bracket 14 is fixed with height-adjustable support feet, and the bottom of the support feet are equipped with shock-absorbing rubber pads. The height of the support feet can be adjusted by horizontal adjustment bolts to adapt to uneven ground.

[0056] Preferably, the temperature sensor 8 is a K-type high-precision thermocouple array with an error of ≤±0.5°C, which can collect the temperature distribution data of the tool head in real time.

[0057] Preferably, the laser sensor 7 is based on laser triangulation and TOF technology to synchronize the position coordinates of the photovoltaic silicon panel with an accuracy of ±0.05mm.

[0058] Preferably, the flow sensor feeds back the flow rate of the cooling medium flow of the air-cooling fan 10 through a thermal mass flow meter with an accuracy of ±1% FS.

[0059] Preferably, the flow sensor, laser sensor 7, temperature sensor 8 and pressure sensor 6 are connected to the main control board via the CAN FD bus protocol. The bandwidth of the CAN FD bus protocol is 5Mbps and the delay is ≤2ms.

[0060] Preferably, the main control board adopts Xilinx Zynq UltraScale+MPSoC chip to realize the collaboration of FPGA hard logic and ARM soft core, the instruction cycle of the operating system (VxWorks) is ≤5ms, the main control board is connected to an industrial-grade touch screen, supports visualization of multi-dimensional data and supports recipe management, and realizes full closed-loop control of sensor-algorithm-actuator through ring redundant topology and priority preemptive scheduling, with synchronization error ≤0.1ms and emergency stop response ≤30ms, which complies with IEC 61508 SIL-2 safety level.

[0061] Preferably, the blade of the double-layer hot blade head 5 is made of a high thermal conductivity material, and the temperature of the blade head is controlled within the range of 200°C-300°C. Within this temperature range, the EVA film will be fully softened, so that the upper glass and the lower back panel can be smoothly separated from the middle silicon solar panel, and thermal damage to the silicon solar cell can be prevented. The control system can automatically adjust the heating power of the electromagnetic induction heating module and the resistance heating module according to the real-time temperature signal fed back by the temperature sensor, and control the temperature fluctuation within a very small range.

[0062] Preferably, the contact pressure between the double-layer hot knife head 5 and the waste photovoltaic silicon battery panel is maintained between 0.5-2N, which helps to control the cutting depth, reduce damage to the silicon battery panel, and improve the cutting accuracy. During the advancement process, the advancement speed of the double-layer hot knife head 5 is accurately measured by the laser sensor 7, and the control system automatically adjusts the advancement speed of the double-layer hot knife head 5 according to the real-time feedback data to maintain the advancement speed at 1-5mm / s. The specific advancement speed can be adjusted according to the size and thickness of the photovoltaic panel to cope with photovoltaic silicon battery panels of different materials and thicknesses, making the cutting process more continuous and accurate, and improving the cutting efficiency.

[0063] Preferably, the surface of the double-layer hot knife head 5 is coated with a boron nitride-based composite insulation layer with a withstand voltage level of ≥15kV and an insulation resistance of >10^12Ω·m, which can prevent electrode short circuit and extend service life.

[0064] Preferably, the double-layer hot knife head 5 adopts a magnetic quick-release interface, supports independent replacement, and is easy to adapt to photovoltaic panels with special shapes, flexibility or thickness ≥5mm. The replacement time takes ≤20 seconds, which improves the equipment maintenance efficiency and compatibility with multiple types of photovoltaic modules.

[0065] Preferably, the air inlet of the air-cooling fan 10 is equipped with a filter for filtering impurities in the air to prevent the impurities from being blown into the copper welding strip absorption device 11, thereby reducing secondary pollution.

[0066] Preferably, an emergency stop button is installed on the bracket 14 to cut off the power supply of the device.

[0067] A novel intelligent method for dismantling waste photovoltaic silicon panels comprises the following steps:

[0068] Step 1: Transfer the waste photovoltaic silicon panels with the frames and aluminum boxes removed to the conveyor belt 2. After entering the feed port 1, the waste photovoltaic silicon panels are firmly clamped by two layers of transmission rollers 3 and are continuously conveyed forward by the conveyor belt;

[0069] Step 2: Preheat the double-layer hot knife head 5 to 200-300°C through the resistance heating module and the electromagnetic induction heating module. Slowly advance the double-layer hot knife head 5 along the laminated interface of the photovoltaic silicon solar cell at a speed of 1-5 mm / s to soften the EVA film and separate the glass and backplane from the silicon solar cell. At the same time, the double-layer hot knife head 5 contacts the copper welding tape and locally heats it for 5-10 seconds to soften the connection between the copper welding tape and the silicon solar cell, thereby separating the copper welding tape from the silicon solar cell.

[0070] During the cutting process, the main control board monitors the temperature, propulsion speed and stress of the double-layer hot knife head 5 and the photovoltaic silicon panel in real time based on the data fed back by the temperature sensor 8, laser sensor 7 and pressure sensor 6;

[0071] The hierarchical decision algorithm dynamically adjusts the magnetic field frequency fem of the electromagnetic induction heating module, the resistance wire current density Jres of the resistance heating module, and the power ratio of the resistance heating module and the electromagnetic induction heating module through fuzzy PID control, so as to control the temperature of the double-layer hot knife head 5 at 200-300°C and make the axial and radial gradients ≤±3°C. The specific process is as follows: the K-type high-precision thermocouple array collects the temperature distribution data of the knife head in real time and inputs it into the fuzzy PID controller, combining the temperature error e(t), the temperature change rate Δe / Δt and the temperature gradient Fuzzy reasoning is performed to dynamically optimize PID parameters (Kp, Ki, Kd) and output control instructions, where: 1) the high-frequency inverter controls fem at 50kHz to 100kHz according to the output of fuzzy PID. When fem>80kHz, the surface of the tool head is focused on for rapid heating to reduce the depth of heat penetration; when fem<60kHz, deep heating is enhanced to balance the axial and radial temperature gradients; 2) the voltage regulator dynamically changes the output voltage according to the output of fuzzy PID, thereby adjusting the current density Jres of the resistance heating module. When 30 <Jres≤50A / mm 2 , for high current density, thus quickly compensating for low temperature areas, suppressing radial and lateral gradients, when 10≤Jres≤30A / mm 2 When the current density is low, the steady-state temperature is maintained to reduce energy consumption; 3) By adjusting fem and Jres, the power ratio of the resistance heating module and the electromagnetic induction heating module is adjusted, so that the temperature is controlled within the set range. In the low temperature range of 200-250°C, the resistance heating module is mainly used for heating, and the ratio of the power Pres of the resistance heating module to the power Pem of the electromagnetic induction heating module is not less than 7:3. The thermal inertia of the resistance heating module is used to compensate for temperature fluctuations; in the high temperature range of 250-300°C, the electromagnetic induction heating module is mainly used for heating, and the ratio of the power Pem of the electromagnetic induction heating module to the power Pres of the resistance heating module is not less than 6:4. The thermal hysteresis is reduced by the high-frequency magnetic field;

[0072] The hierarchical decision algorithm adjusts the speed of the conveyor belt 2 according to the position coordinates of the double-layer hot knife head 5 to control the advancing speed of the double-layer hot knife head 5;

[0073] At the same time, the hierarchical decision-making algorithm diagnoses abnormal signals and determines the integrity of the waste photovoltaic silicon panels;

[0074] Step 3: The main control board controls the six-axis servo robot arm to drive the vacuum suction cup array 4 to move to the glass and absorb the glass. Then, the six-axis servo robot arm drives the vacuum suction cup array 4 to transfer the glass to the glass collection bin 12.

[0075] Step 4: After the backboard is transported to the discharge port 16 by the conveyor belt 2, it falls into the backboard collection bin 9 under the action of gravity;

[0076] Step 5: The copper soldering tape attached to the silicon solar cell panel is further conveyed forward by the conveyor belt 2. The air-cooling fan 10 is started. The high-speed fan generates forced convection dry air to quickly reduce the temperature of the silicon solar cell panel. Under the blowing of the airflow, the softened copper soldering tape is completely peeled off from the surface of the silicon solar cell and blown into the copper soldering tape absorption device 11 located opposite the air-cooling fan 10.

[0077] During the purge process, the main control board adjusts the wind speed and flow of the air-cooling fan 10 according to the data uploaded by the flow sensor, adjusts the speed of the high-speed fan to control the wind speed and flow of the air-cooling fan 10, and detects the surface temperature of the silicon cell according to the infrared imager 15 until its surface temperature is completely cooled to normal temperature and then transported to the next process.

[0078] Application Examples

[0079] The technicians transfer the pre-treated waste photovoltaic silicon solar panels to the conveyor belt 2. After the waste photovoltaic silicon solar panels enter the feed port 1, they are firmly clamped by two layers of transmission rollers 3 to prevent the photovoltaic panels from shifting during the cutting process; the double-layer hot knife head 5 is preheated to 200-300 ° C, and the double-layer hot knife head 5 is slowly advanced along the laminated interface of the photovoltaic panel at a set advancement speed to soften the EVA film and separate the glass and backplane from the silicon solar cell. During the cutting process, the control system monitors the temperature, advancement speed and stress of the double-layer hot knife head 5 in real time based on the data fed back by the temperature sensor 8, laser sensor 7 and pressure sensor 6, and automatically adjusts the parameters, or the technicians give appropriate human intervention based on the data uploaded to the touch screen by the control system to make the cutting more accurate and stable. At the same time, the technology Personnel use the laser sensor 7 to accurately position the blade to contact the copper soldering tape, and locally heat it for 5-10 seconds to soften the connection between the copper soldering tape and the silicon solar cell. The vacuum suction cup array absorbs the peeled glass and moves it to the glass collection bin 12. The backplane falls into the backplane collection bin 9 below. The copper soldering tape adheres to the silicon solar cell and is transported forward. The air-cooling fan 10 is started, and the high-speed fan generates forced convection dry air to quickly reduce the temperature of the silicon solar cell. Under the blowing of the airflow, the softened copper soldering tape is completely peeled off from the surface of the silicon solar cell. The copper soldering tape is blown into the copper soldering tape absorption device 11 opposite the air-cooling fan 10. During the blowing process, the surface temperature of the silicon solar cell is detected by the infrared imager 15 until its surface temperature is completely cooled to normal temperature, and then it is transported to the next process by the conveyor belt 2.

Claims

1. A new intelligent device for dismantling waste photovoltaic silicon panels, characterized in that: The invention comprises a control system, a conveyor belt (2), a transmission roller (3) and a bracket (14); the transmission roller (3) is provided with two layers; the conveyor belt (2) runs through the two layers of transmission rollers (3); and a gap is left between the conveyor belt (2) and the upper layer of transmission rollers (3) for the passage of waste photovoltaic silicon battery panels; the gap between the starting end of the upper layer of transmission rollers (3) and the conveyor belt (2) constitutes a feed port (1); and the gap between the tail end of the upper layer of transmission rollers (3) and the tail end of the conveyor belt (2) constitutes a discharge port (16); The control system is a main control board that integrates a fuzzy controller and a PID controller. The main control board is deployed with a hierarchical decision algorithm and a BP neural network. The PID controller and the fuzzy controller are connected, and the BP neural network is used to dynamically adjust the PID parameters of the PID controller. A six-axis servo motor is fixedly mounted on the top of the bracket (14); an end effector of the six-axis servo motor is fixedly connected to a vacuum suction cup array (4); a back plate collection bin (9), an air-cooling fan (10) and a copper-welding strip absorption device (11) are fixedly mounted on the tail end of the bracket (14); an air outlet of the air-cooling fan (10) is opposite to an inlet of the copper-welding strip absorption device (11); an infrared imager (15) is fixedly mounted on the air outlet of the air-cooling fan (10); The bracket (14) is provided with a double-layer hot knife head (5), and the outer surface of the double-layer hot knife head (5) is embedded with a resistance heating module and an electromagnetic induction heating module, wherein: the electromagnetic induction heating module is connected to the PID controller and is externally connected to a DC power supply through a high-frequency inverter; the resistance heating module is respectively connected to the PID controller and the output end of the voltage regulator, and the input end of the voltage regulator is connected to the DC power supply; The double-layer hot knife head (5) is fixedly mounted with a pressure sensor (6), a laser sensor (7) and a temperature sensor (8); the pressure sensor (6), the laser sensor (7), the temperature sensor (8) and the infrared imager (15) are all connected to a main control board; the real-time data collected by the pressure sensor (6), the laser sensor (7), the temperature sensor (8) and the infrared imager (15) serve as inputs of a hierarchical decision algorithm, and the main control board uses the output of the hierarchical decision algorithm as a control signal.

2. The novel intelligent device for dismantling waste photovoltaic silicon panels according to claim 1 is characterized in that: Ceramic heat insulation plates (13) are fixedly mounted on both sides of the bracket (14), and the transmission roller (3), the conveyor belt (2) and the double-layer hot knife head (5) are all located between a pair of ceramic heat insulation plates (13).

3. The novel intelligent device for dismantling waste photovoltaic silicon panels according to claim 2 is characterized in that: The transmission roller (3) comprises a mounting frame and a plurality of evenly distributed rollers rotatably connected to the mounting frame, wherein a pressure sensor (6) is installed below the mounting frame of the transmission roller (3) on the upper layer, and ball screws are respectively installed at the front and rear ends thereof, and the ball screws are connected to the stepping motor; The pressure sensor (6) and the stepping motor are both connected to the main control board.

4. The novel intelligent device for dismantling waste photovoltaic silicon panels according to any one of claims 1 to 3, characterized in that: A flow sensor is also fixedly installed at the air outlet of the air-cooling fan (10), and the flow sensor is connected to the main control board.

5. The novel intelligent device for dismantling waste photovoltaic silicon panels according to claim 4 is characterized in that: The flow sensor, laser sensor (7), temperature sensor (8) and pressure sensor (6) are all connected to the main control board via the CAN FD bus protocol.

6. The novel intelligent device for dismantling waste photovoltaic silicon panels according to any one of claims 1 to 3, characterized in that: The electromagnetic induction heating module is a copper alloy coil spirally wound on the outer surface of the blade of the double-layer hot blade (5); The resistance heating module is a nickel-chromium alloy wire array embedded in the cutter head, and the nickel-chromium alloy wire array and the copper alloy coil are staggered.

7. The novel intelligent device for dismantling waste photovoltaic silicon panels according to any one of claims 1 to 3, characterized in that: The utility model also includes a touch screen, which is connected to the main control board.

8. The novel intelligent device for dismantling waste photovoltaic silicon panels according to any one of claims 1 to 3, characterized in that: A height-adjustable support foot is fixedly mounted on the bottom of the bracket (14), and a shock-absorbing rubber pad is fixedly mounted on the bottom of the support foot.

9. The novel intelligent device for dismantling waste photovoltaic silicon panels according to any one of claims 1 to 3, characterized in that: The surface of the double-layer hot knife head (5) is coated with a boron nitride-based composite insulation layer.

10. A novel intelligent method for dismantling waste photovoltaic silicon panels based on the device according to any one of claims 1 to 3, characterized in that: The steps include: Step 1: The waste photovoltaic silicon solar panels with frames and aluminum boxes removed are transferred to a conveyor belt (2). The waste photovoltaic silicon solar panels enter the feed port (1), are firmly clamped by two layers of transmission rollers (3), and continue to be conveyed forward; Step 2: preheat the double-layer hot knife head (5) to 200-300° C. through the resistance heating module and the electromagnetic induction heating module, and slowly advance the double-layer hot knife head (3) along the laminated interface of the photovoltaic silicon solar cell at a set advancing speed to soften the EVA film and separate the glass and backboard from the silicon solar cell; at the same time, the double-layer hot knife head (5) contacts the copper welding tape and locally heats it for 5-10 seconds to soften the connection between the copper welding tape and the silicon solar cell, and separate the copper welding tape from the silicon solar cell; During the cutting process, the temperature sensor (8), the laser sensor (7) and the pressure sensor (6) upload the collected temperature, position coordinates and pressure data of the double-layer hot knife head (5) to the main control board. The hierarchical decision algorithm deployed on the main control board uses the temperature, coordinates and pressure data as input to monitor the temperature, propulsion speed and pressure of the double-layer hot knife head (5) in real time. The hierarchical decision algorithm utilizes fuzzy PID control to dynamically adjust the magnetic field frequency fem of the electromagnetic induction heating module, the resistance wire current density Jres of the resistance heating module, and the power ratio of the resistance heating module and the electromagnetic induction heating module, so as to control the temperature of the double-layer hot cutter head (5) at 200-300°C and make the axial and radial gradients ≤±3°C. The specific process is as follows: the temperature sensor (8) collects the temperature data distributed on the cutter head in real time and inputs it into the fuzzy PID controller, and combines the temperature error e(t), the temperature change rate Δe / Δt and the temperature gradient to obtain the temperature data. Perform fuzzy reasoning, dynamically optimize PID parameters, and output control instructions, wherein: the high-frequency inverter controls fem at 50kHz to 100kHz according to the output of fuzzy PID. When fem>80kHz, focus on rapid heating of the surface of the cutter head to reduce the depth of heat penetration; when fem<60kHz, enhance deep heating to balance the axial and radial temperature gradients; the voltage regulator dynamically changes the output voltage according to the output of fuzzy PID, adjusts the current density Jres of the resistance heating module, and when 30 <Jres≤50A / mm 2 , quickly compensate for low temperature areas, suppress radial and lateral gradients, when 10≤Jres≤30A / mm 2 When heating, the steady-state temperature is maintained and energy consumption is reduced; by adjusting fem and Jres, the power ratio of the resistance heating module and the electromagnetic induction heating module is adjusted. In the low temperature range of 200-250℃, the ratio of the power Pres of the resistance heating module to the power Pem of the electromagnetic induction heating module is not less than 7:3, and the thermal inertia of the resistance heating module is used to compensate for temperature fluctuations; in the high temperature range of 250-300℃, the ratio of the power Pem of the electromagnetic induction heating module to the power Pres of the resistance heating module is not less than 6:4, and thermal hysteresis is reduced by a high-frequency magnetic field; The hierarchical decision algorithm dynamically adjusts the propulsion speed of the double-layer hot knife head (5) according to the position coordinates of the double-layer hot knife head (5), and controls the pressure on the photovoltaic silicon battery panel to be between 0.5-2N; Step 3: The main control board controls the six-axis servo mechanical arm to drive the vacuum suction cup array (4) to move onto the glass and absorb the glass. Then, the six-axis servo mechanical arm drives the vacuum suction cup array (4) to transfer the glass to the glass collection bin (12). Step 4: After the backboard is transported to the discharge port (16) by the conveyor belt (2), it falls into the backboard collection bin (9) under the action of gravity; Step 5: The copper soldering tape attached to the silicon solar cell panel is continuously conveyed forward by the conveyor belt (2), and the air-cooling fan (10) is started. The high-speed fan generates forced convection dry air to quickly reduce the temperature of the silicon solar cell panel. Under the blowing of the air flow, the softened copper soldering tape is completely peeled off from the surface of the silicon solar cell, and the copper soldering tape is blown into the copper soldering tape absorption device (11) located opposite the air-cooling fan (10); During the purging process, the main control board monitors the surface temperature of the silicon cell using the infrared imager (15) until the surface temperature is completely cooled to normal temperature and then transported to the next process.

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