Photovoltaic module vacuum lamination system based on dynamic pressure feedback and control method thereof

Abstract

The invention relates to the technical field of photovoltaic module manufacturing, in particular to a photovoltaic module vacuum laminating system based on dynamic pressure feedback. The dynamic pressure adjusting module comprises a piezoelectric film sensor and a servo motor, the piezoelectric film sensor is used for detecting the pressure borne by the photovoltaic module, and the control module calculates and obtains the real-time optimal pressure and then controls the servo motor to act so as to achieve the real-time optimal pressure; the heating control module comprises a heating plate, a thermal infrared imager and a PID temperature control unit, the heating plate is used for heating the photovoltaic module, the thermal infrared imager is used for detecting the surface temperature distribution of the photovoltaic module, and the PID temperature control unit is used for controlling the temperature of the heating plate; the vacuum control module comprises a plurality of air chambers which are independently arranged, each air chamber is provided with an air inlet pipeline and an air outlet pipeline which are communicated with the laminating machine cavity, and micro electromagnetic valves are arranged on the air inlet pipelines and the air outlet pipelines.

Description

Technical Field

[0001] The present invention relates to the technical field of photovoltaic module manufacturing, and in particular to a photovoltaic module vacuum lamination system based on dynamic pressure feedback and a control method thereof. Background Art

[0002] In photovoltaic module manufacturing, vacuum lamination is typically used. This process involves hot-pressing the cell strings, EVA / POE film, backsheet, and glass. The laminator forms a closed chamber using upper and lower layers of silicone sheets and strips. Once the module is in this closed chamber, it is evacuated and heated to melt the EVA / POE film. This vacuum is then used to extract air bubbles from the module, allowing the layers to come into close contact and achieve adhesion. Traditional laminators suffer from uneven pressure distribution during the lamination process. Too little pressure can easily result in bubbles remaining after the EVA cross-links and cures, while too much pressure can easily lead to hidden cracks in the cell.

[0003] In view of this, we proposed a photovoltaic module vacuum lamination system based on dynamic pressure feedback and its control method. Summary of the Invention

[0004] The purpose of the present invention is to provide a photovoltaic module vacuum lamination system based on dynamic pressure feedback and a control method thereof, so as to solve the problems raised in the above background technology.

[0005] To achieve the above objectives, one aspect of the present invention provides a photovoltaic module vacuum lamination system based on dynamic pressure feedback, comprising:

[0006] Control module;

[0007] The dynamic pressure regulation module includes a piezoelectric film sensor and a servo motor. The piezoelectric film sensor is used to detect the pressure on the photovoltaic module. The control module calculates the real-time optimal pressure and then controls the servo motor to achieve the real-time optimal pressure.

[0008] A heating control module includes a heating plate, an infrared thermal imager, and a PID temperature control unit. The heating plate is used to heat the photovoltaic module. The infrared thermal imager is used to detect the surface temperature distribution of the photovoltaic module. The PID temperature control unit is used to control the temperature of the heating plate.

[0009] The vacuum control module includes a plurality of independently arranged air chambers. Each air chamber is provided with an air intake pipeline and an exhaust pipeline connected to the laminator chamber. The air intake pipeline and the exhaust pipeline are provided with micro electromagnetic valves.

[0010] Preferably, the control module calculates and obtains the real-time optimal pressure including:

[0011] Establish EVA melt rheological equation:

[0012]

[0013] In formula (1), η represents the real-time viscosity of EVA, T represents the real-time temperature, t represents the heating time, A represents the zero shear viscosity reference, B represents the activation energy coefficient, C represents the shear thinning intensity coefficient, D represents the shear thinning index, and γ represents the shear rate;

[0014] The real-time optimal pressure is calculated based on the real-time viscosity η of EVA. The calculation method is as follows:

[0015]

[0016] In formula (2), N represents the correlation parameter between pressure and viscosity, and N is calculated based on the bubble rate:

[0017]

[0018] In formula (3), N1 represents the reference value of the correlation parameter, F represents the actual bubble rate, and F1 represents the target bubble rate.

[0019] Preferably, the control system causes the temperature of the heating plate to change gradually through a PID temperature control unit.

[0020] Preferably, the gradient change of the heating plate temperature specifically includes:

[0021] Preheating section: raise the temperature of the heating plate from 80±2℃ to 120±2℃;

[0022] Cross-linking stage: raise the temperature of the heating plate from 120±2℃ to 150±2℃;

[0023] Stabilization stage: reduce the temperature of the heating plate from 150±2℃ to 100±2℃.

[0024] Preferably, the control module is also used to control the opening of the micro electromagnetic valves on the air intake pipe and the exhaust pipe, so that the vacuum degree in the laminator chamber changes gradually.

[0025] Preferably, the gradient change of the vacuum degree in the laminator chamber is coordinated with the gradient change of the temperature of the heating plate, specifically including:

[0026] Preheating stage: Rapidly evacuate to -70±1kPa;

[0027] Cross-linking stage: switch to -50±1kPa and pulse oscillate;

[0028] Stable stage: Maintain pressure at -20±1kPa.

[0029] Preferably, the duration of the preheating section is 2.5 to 3.5 minutes, the duration of the crosslinking section is 2.5 to 3.5 minutes, and the duration of the stabilization section is 0.5 to 1.5 minutes.

[0030] Another aspect of the present invention provides a control method for a photovoltaic module vacuum lamination system based on dynamic pressure feedback, which is applicable to the photovoltaic module vacuum lamination system based on dynamic pressure feedback as described above, and includes the following steps:

[0031] S1. The photovoltaic module lamination process is divided into a preheating stage, a cross-linking stage, and a stabilization stage. The control system uses a PID temperature control unit to make the heating plate temperature change gradually in different stages.

[0032] S2. The control module controls the opening of the micro-solenoid valves on the air intake and exhaust pipes to make the vacuum degree in the laminator chamber change gradually, in coordination with the temperature gradient of the heating plate;

[0033] S3. After the control module calculates and obtains the real-time optimal pressure, it controls the servo motor to achieve the real-time optimal pressure.

[0034] Compared with the prior art, the present invention has the following beneficial effects:

[0035] The photovoltaic module vacuum lamination system based on dynamic pressure feedback proposed in the present invention calculates the real-time viscosity of EVA by establishing the EVA melt rheological equation, and then obtains the real-time optimal pressure, thereby realizing precise control of the pressure, avoiding the problem of residual bubbles due to too low pressure or hidden cracks due to excessive pressure during the lamination process; by coordinating the gradient change of the chamber vacuum degree with the gradient change of the heating plate temperature, combined with dynamic pressure regulation, the EVA curing reaction can be promoted, the EVA can be quickly cured, the lamination process production time can be shortened, the production efficiency can be improved, and energy consumption can be saved. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 This is a structural block diagram of the photovoltaic module vacuum lamination system based on dynamic pressure feedback provided by the present invention.

[0037] Figure 2 This is a flow chart of the control method of the photovoltaic module vacuum lamination system based on dynamic pressure feedback provided by the present invention. DETAILED DESCRIPTION

[0038] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0039] Figure 1The embodiment of the present invention provides a photovoltaic module vacuum lamination system based on dynamic pressure feedback, such as Figure 1 As shown, including:

[0040] Control module;

[0041] The dynamic pressure regulation module includes a piezoelectric film sensor and a servo motor. The piezoelectric film sensor is used to detect the pressure on the photovoltaic module. The control module calculates the real-time optimal pressure and then controls the servo motor to achieve the real-time optimal pressure.

[0042] A heating control module includes a heating plate, an infrared thermal imager, and a PID temperature control unit. The heating plate is used to heat the photovoltaic module. The infrared thermal imager is used to detect the surface temperature distribution of the photovoltaic module. The PID temperature control unit is used to control the temperature of the heating plate.

[0043] The vacuum control module includes a plurality of independently arranged air chambers. Each air chamber is provided with an air intake pipeline and an exhaust pipeline connected to the laminator chamber. The air intake pipeline and the exhaust pipeline are provided with micro electromagnetic valves.

[0044] The photovoltaic module vacuum lamination system based on dynamic pressure feedback proposed in the present invention obtains the real-time optimal pressure through calculation by the control module, and then controls the servo motor action of the dynamic pressure regulation module to achieve the real-time optimal pressure, thereby realizing precise control of the pressure, avoiding the problem of residual bubbles due to too low pressure or hidden cracks due to excessive pressure during the lamination process; the surface temperature distribution of the photovoltaic module is detected by the infrared thermal imager (resolution 0.1°C) of the heating control module, and the PID temperature control unit is linked to implement temperature control on the heating plate; the vacuum degree of the laminator chamber is regulated by multiple independent air chambers of the vacuum control module.

[0045] In one embodiment of the present invention, the control module calculates and obtains the real-time optimal pressure, including:

[0046] Establish EVA melt rheological equation:

[0047]

[0048] In formula (1), η represents the real-time viscosity of EVA, T represents the real-time temperature, t represents the heating time, A represents the zero shear viscosity reference, B represents the activation energy coefficient, C represents the shear thinning intensity coefficient, D represents the shear thinning index, and γ represents the shear rate;

[0049] In an embodiment of the present invention, A is 1.5×10 -5 to 1.8×10 -5Pa·s, B is 4300 to 4700 K, C is 0.7 to 0.8, and D is 0.3 to 0.5, obtained by real-time γ detection;

[0050] The real-time optimal pressure is calculated based on the real-time viscosity η of EVA. The calculation method is as follows:

[0051]

[0052] In formula (2), P represents pressure, N represents the correlation parameter between pressure and viscosity, and N is calculated based on the bubble rate:

[0053]

[0054] In formula (3), N1 represents the reference value of the correlation parameter, F represents the actual bubble rate (obtained by real-time detection), and F1 represents the target bubble rate (pre-set).

[0055] The negative pressure created by vacuuming promotes closer contact between EVA molecules, which encourages more frequent collisions, increases the probability of reaction, and enables a more complete curing reaction. By establishing an EVA melt rheology equation to calculate the real-time viscosity of the EVA, the optimal real-time pressure is obtained, enabling precise pressure control.

[0056] In one embodiment of the present invention, the control system causes the temperature of the heating plate to change gradually through a PID temperature control unit.

[0057] Furthermore, the gradient change of the heating plate temperature specifically includes:

[0058] Preheating section: Raise the temperature of the heating plate from 80±2℃ to 120±2℃ to initially melt the EVA;

[0059] Cross-linking stage: Raise the temperature of the heating plate from 120±2℃ to 150±2℃ to trigger the decomposition of peroxide;

[0060] Stabilization stage: Reduce the temperature of the heating plate from 150±2℃ to 100±2℃ and cool slowly to reduce thermal stress.

[0061] In one embodiment of the present invention, the control module is further configured to control the opening of the micro-solenoid valves on the air intake pipe and the exhaust pipe, so as to cause a gradient change in the vacuum degree in the laminator chamber.

[0062] Furthermore, the gradient change of the vacuum degree in the laminator chamber is coordinated with the gradient change of the temperature of the heating plate, specifically including:

[0063] Preheating stage: Rapidly evacuate to -70±1kPa to remove large bubbles;

[0064] Cross-linking stage: switch to -50±1kPa and pulse oscillate to promote the escape of small bubbles;

[0065] Stable stage: Maintain pressure at -20±1kPa to balance cross-linking shrinkage stress.

[0066] The present invention coordinates the gradient change of the chamber vacuum degree with the gradient change of the heating plate temperature, and combines it with dynamic pressure regulation to promote the EVA curing reaction, realize rapid curing of EVA, shorten the production time of the lamination process, improve production efficiency and save energy consumption.

[0067] In an embodiment of the present invention, the preheating stage is 2.5 to 3.5 minutes long, the crosslinking stage is 2.5 to 3.5 minutes long, and the stabilization stage is 0.5 to 1.5 minutes long. Preferably, the preheating stage is 3 minutes long, the crosslinking stage is 3 minutes long, and the stabilization stage is 1 minute long.

[0068] Figure 2 The flowchart of the control method of the photovoltaic module vacuum lamination system based on dynamic pressure feedback provided by the present invention. Figure 2 As shown, an embodiment of the present invention further provides a control method for a photovoltaic module vacuum lamination system based on dynamic pressure feedback, comprising the following steps:

[0069] S1. The photovoltaic module lamination process is divided into a preheating stage, a cross-linking stage, and a stabilization stage. The control system uses a PID temperature control unit to make the heating plate temperature change gradually in different stages.

[0070] S2. The control module controls the opening of the micro-solenoid valves on the air intake and exhaust pipes to make the vacuum degree in the laminator chamber change gradually, in coordination with the temperature gradient of the heating plate;

[0071] S3. After the control module calculates and obtains the real-time optimal pressure, it controls the servo motor to achieve the real-time optimal pressure.

[0072] Working principle: By establishing the EVA melt rheology equation to calculate the real-time viscosity of EVA, and then obtaining the real-time optimal pressure, precise control of pressure is achieved to avoid the problem of residual bubbles due to too little pressure or hidden cracks due to too much pressure during the lamination process; by coordinating the gradient change of the chamber vacuum degree with the gradient change of the heating plate temperature, the EVA curing reaction can be promoted. Combined with dynamic pressure regulation, rapid curing of EVA can be achieved, shortening the production time of the lamination process, improving production efficiency and saving energy. The total process time for producing photovoltaic modules through the implementation of the present invention is shortened to 30%, the EL test hidden crack rate is reduced by 40%, the bubble area accounts for <0.01%, and the heating energy consumption is reduced by 20% through precise temperature control.

[0073] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. Photovoltaic module vacuum lamination system based on dynamic pressure feedback, characterized in that: include: Control module; The dynamic pressure regulation module includes a piezoelectric film sensor and a servo motor. The piezoelectric film sensor is used to detect the pressure on the photovoltaic module. The control module calculates the real-time optimal pressure and then controls the servo motor to achieve the real-time optimal pressure. A heating control module includes a heating plate, an infrared thermal imager, and a PID temperature control unit. The heating plate is used to heat the photovoltaic module. The infrared thermal imager is used to detect the surface temperature distribution of the photovoltaic module. The PID temperature control unit is used to control the temperature of the heating plate. The vacuum control module includes a plurality of independently arranged air chambers. Each air chamber is provided with an air intake pipeline and an exhaust pipeline connected to the laminator chamber. The air intake pipeline and the exhaust pipeline are provided with micro electromagnetic valves.

2. The photovoltaic module vacuum lamination system based on dynamic pressure feedback according to claim 1, characterized in that: The control module calculates and obtains the real-time optimal pressure including: Establish EVA melt rheological equation: In formula (1), η represents the real-time viscosity of EVA, T represents the real-time temperature, t represents the heating time, A represents the zero shear viscosity reference, B represents the activation energy coefficient, C represents the shear thinning intensity coefficient, D represents the shear thinning index, and γ represents the shear rate; The real-time optimal pressure is calculated based on the real-time viscosity η of EVA. The calculation method is as follows: In formula (2), N represents the correlation parameter between pressure and viscosity, and N is calculated based on the bubble rate: In formula (3), N1 represents the reference value of the correlation parameter, F represents the actual bubble rate, and F1 represents the target bubble rate.

3. The photovoltaic module vacuum lamination system based on dynamic pressure feedback according to claim 2, characterized in that: The control system uses a PID temperature control unit to change the temperature of the heating plate in a gradient manner.

4. The photovoltaic module vacuum lamination system based on dynamic pressure feedback according to claim 3, characterized in that: The gradient change of the heating plate temperature specifically includes: Preheating section: raise the temperature of the heating plate from 80±2℃ to 120±2℃; Cross-linking stage: raise the temperature of the heating plate from 120±2℃ to 150±2℃; Stabilization stage: reduce the temperature of the heating plate from 150±2℃ to 100±2℃.

5. The photovoltaic module vacuum lamination system based on dynamic pressure feedback according to claim 4, characterized in that: The control module is also used to control the opening of the micro solenoid valves on the air intake and exhaust pipes, so that the vacuum degree in the laminator chamber changes gradually.

6. The photovoltaic module vacuum lamination system based on dynamic pressure feedback according to claim 5, characterized in that: The gradient change of vacuum degree in the laminator chamber is coordinated with the gradient change of heating plate temperature, specifically including: Preheating stage: Rapidly evacuate to -70±1kPa; Cross-linking stage: switch to -50±1kPa and pulse oscillate; Stable stage: Maintain pressure at -20±1kPa.

7. The photovoltaic module vacuum lamination system based on dynamic pressure feedback according to claim 6, characterized in that: The duration of the preheating section is 2.5 to 3.5 minutes, the duration of the cross-linking section is 2.5 to 3.5 minutes, and the duration of the stabilization section is 0.5 to 1.5 minutes.

8. A control method for a photovoltaic module vacuum lamination system based on dynamic pressure feedback, characterized in that: A photovoltaic module vacuum lamination system based on dynamic pressure feedback according to any one of claims 1 to 7, comprising the following steps: S1. The photovoltaic module lamination process is divided into a preheating stage, a cross-linking stage, and a stabilization stage. The control system uses a PID temperature control unit to make the heating plate temperature change gradually in different stages. S2. The control module controls the opening of the micro-solenoid valves on the air intake and exhaust pipes to make the vacuum degree in the laminator chamber change gradually, in coordination with the temperature gradient of the heating plate; S3. After the control module calculates and obtains the real-time optimal pressure, it controls the servo motor to achieve the real-time optimal pressure.

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