A junction box installation production line and installation method

Abstract

This invention discloses a junction box installation production line and method, relating to the field of photovoltaic module production equipment technology. The junction box installation production line includes a frame, a PLC system module, a vision inspection system, two parallel main conveyor belts on the frame, and multiple lifting mechanisms. Along the conveying direction of the main conveyor belts, a junction box gluing mechanism, a soldering and soldering mechanism, a power detection and sorting mechanism, and a glue-filling mechanism are sequentially arranged across the frame. A junction box pre-processing mechanism is also provided on the frame. The PLC system module is signal-connected to the vision inspection system, lifting mechanisms, junction box pre-processing mechanism, flipping mechanism, gluing mechanism, soldering mechanism, power detection and sorting mechanism, and glue-filling mechanism, respectively. The PLC system module provides overall control, achieving automated junction box installation and improving installation efficiency and quality.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic module production equipment technology, specifically a junction box installation production line and installation method. Background Technology

[0002] In the photovoltaic (PV) module industry, to reduce costs, improve efficiency, and enhance quality, using metal foils such as copper and aluminum foil to prepare busbar structures is an alternative process. PV modules made using this type of busbar are called copper (aluminum) foil modules. Compared to conventional PV modules, the positive and negative leads of copper (aluminum) foil modules do not extend in the form of long, bent busbars. Instead, they are exposed on the backsheet surface as flat electrode contacts through busbar outlets on the backsheet. When installing the junction box for copper (aluminum) foil modules, the lower junction box needs to be glued to the backsheet surface of the PV module, and the backsheet electrode contacts need to be soldered to the terminals inside the junction box. Then, the solder joints are sealed with grout to achieve sealing and protection of the external output circuit of the PV module.

[0003] Currently, there are some automated junction box installation devices for conventional photovoltaic modules, but these devices cannot adapt to the process characteristics of the "flat lead-out end" of copper (aluminum) foil modules. As a result, the junction box installation of copper (aluminum) foil modules is carried out manually, which has problems such as low efficiency, unstable welding quality and poor potting effect. Therefore, the industry urgently needs to provide an automated production line for the junction box installation of copper (aluminum) foil modules. Summary of the Invention

[0004] The purpose of this invention is to provide a junction box installation production line to solve the problems mentioned in the prior art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: the junction box installation production line includes a frame, a PLC system module, a vision inspection system, and two parallel main conveyor belts and multiple lifting mechanisms set on the frame, wherein the two main conveyor belts are used to transport photovoltaic modules; The frame is sequentially and transversely arranged along the main conveyor belt conveying direction, including a box gluing mechanism, a soldering mechanism, a power detection and sorting mechanism, and a glue dispensing mechanism; The frame is also equipped with a junction box pretreatment mechanism, and a flipping mechanism is provided between the unloading position of the junction box pretreatment mechanism and the gluing mechanism. The mounting locations of the box-gluing mechanism, the soldering mechanism, the welding mechanism, the power detection mechanism, the sorting mechanism, and the glue-filling mechanism are respectively located at the box-gluing station, the soldering station, the welding station, the power detection station, and the glue-filling station. The vision inspection system includes multiple cameras installed above the box-gluing station, the soldering station, the welding station, the power detection station, and the glue-filling station. The multiple cameras are used to capture position images of the photovoltaic module and the target area of ​​the junction box. The PLC system module is signal-connected to the vision inspection system, the main conveyor belt, the lifting mechanism, the junction box pretreatment mechanism, the flipping mechanism, the box gluing mechanism, the soldering mechanism, the welding mechanism, the power detection and sorting mechanism, and the glue dispensing mechanism.

[0006] As a preferred technical solution, the junction box pretreatment mechanism includes: a feeding unit, a conveying unit, a loading unit, a cleaning unit, and a glue application unit; The feeding unit includes a vibratory feeder and a junction box conveyor belt, used for sorting and outputting the junction boxes; The conveying unit includes a rotary table and a plurality of molds arranged around the circumference of the rotary table, the plurality of molds being used to support the junction box; The feeding unit is used to grab the junction box from the end of the junction box conveyor belt and place it in the mold; The cleaning unit is used to perform plasma cleaning on the bonding surface of the junction box in the mold; The glue application unit is used to apply adhesive to the bonding surface of the junction box in the mold.

[0007] As a preferred technical solution, the flipping mechanism is provided with a first Z-axis servo module, which is vertically connected and installed on the frame. A flipping cylinder is installed on the slider of the first Z-axis servo module, and a cylinder gripper is connected to the output end of the flipping cylinder. The cylinder gripper is used to grip the pre-processed junction box from the unloading position of the junction box pre-processing mechanism and is driven by the flipping cylinder to rotate 180° in the horizontal plane.

[0008] As a preferred technical solution, the gluing mechanism is provided with a first Y-axis servo module, a first X-axis servo module, a second Z-axis servo module, and a first Z-axis cylinder. The first Z-axis cylinder is connected and installed on the slider of the second Z-axis servo module. A pneumatic gripper is connected and installed at the output end of the first Z-axis cylinder. A probe is also connected and installed on the slider of the second Z-axis servo module. The pneumatic gripper is used to grip the junction box from the cylinder gripper, and the probe is used to contact the electrode contacts on the backsheet of the photovoltaic module to perform a continuity test.

[0009] As a preferred technical solution, the soldering mechanism is provided with a second Y-axis servo module, a second X-axis servo module, and a second Z-axis cylinder. The second Z-axis cylinder is connected to a clamping component, which clamps a solder paste tube. A back suction component for controlling the amount of solder paste is installed at the upper end of the solder paste tube.

[0010] As a preferred technical solution, the welding mechanism includes a third Y-axis servo module, a third X-axis servo module, and a third Z-axis cylinder. A welding torch head is installed at the output end of the third Z-axis cylinder, and a welding power supply is provided on the frame. The welding torch head is powered by the welding power supply.

[0011] As a preferred technical solution, the power detection and sorting mechanism includes a driving element, a light source, a detection head, a suction cup, and a non-conforming product conveyor belt; The driving components include a fourth Y-axis servo module, a fourth X-axis servo module, a third Z-axis servo module, and a fourth Z-axis cylinder; The light source is positioned below the power detection station to provide simulated illumination for the photovoltaic module; The detection head is connected to the output end of the fourth Z-axis cylinder and is used to make electrical contact with the positive and negative output terminals of the junction box for power detection. The suction cup is connected to the slider of the third Z-axis servo module and is used to adsorb defective products; the defective product conveyor belt is installed on one side of the frame and is used to transport defective products.

[0012] As a preferred technical solution, the glue dispensing mechanism is equipped with a fifth Y-axis servo module, a fifth X-axis servo module, a fifth Z-axis cylinder, and a glue storage tank. The output end of the fifth Z-axis cylinder is connected to a glue gun, and the glue gun is connected to the glue storage tank through a glue delivery pipe. A solenoid valve for controlling the glue path is provided on the glue delivery pipe.

[0013] As a preferred technical solution, the visual inspection system includes a first camera, a second camera, a third camera, a fourth camera, and a fifth camera; The first camera is located above the gluing station and is used to capture the position image of the back electrode contact of the photovoltaic module and upload it to the PLC system module. The second camera is located above the soldering station and is used to capture position images inside the junction box and upload them to the PLC system module. The third camera is located above the welding station and is used to capture position images inside the junction box and upload them to the PLC system module. The fourth camera is located above the power detection station and is used to capture position images inside the junction box and upload them to the PLC system module. The fifth camera is located above the glue-filling station and is used to capture position images inside the junction box and upload them to the PLC system module.

[0014] An installation method for a junction box installation production line: Step 1: Place the photovoltaic module on the feeding end of the main conveyor belt, while the junction box pretreatment mechanism feeds, cleans, and applies glue to the junction box. Step 2: The photovoltaic module is transported to the gluing station and positioned. The vision inspection system collects the position image of the electrode contact point on the back panel of the photovoltaic module. The PLC system module performs appearance inspection and positioning. The gluing mechanism performs a continuity test on the photovoltaic module contact. The gluing mechanism takes the flipped and pre-processed junction box from the flipping mechanism and glues it to the back panel of the photovoltaic module. Step 3: The photovoltaic module is transported to the soldering station and positioned. The vision inspection system collects the position image inside the junction box. The PLC system module performs appearance inspection and solder joint positioning. The soldering mechanism applies solder paste to the solder joints inside the junction box. Step 4: The photovoltaic module is transported to the welding station and positioned. The vision inspection system collects the position image inside the junction box. The PLC system module performs appearance inspection and weld point positioning. The welding mechanism welds the weld points. Step 5: The photovoltaic module is transported to the power detection station and positioned. The vision inspection system acquires the position image inside the junction box. The PLC system module performs appearance inspection and positioning. The power detection and sorting mechanism measures the operating current of the photovoltaic module under a set voltage. The PLC system module calculates the output power based on the set voltage and the measured operating current, and compares it with the preset power value to determine whether it is qualified. The power detection and sorting mechanism sorts out the unqualified products. Step Six: The photovoltaic module is transported to the glue-filling station and positioned. The vision inspection system collects the position image inside the junction box. The PLC system module performs appearance inspection and positioning. The glue-filling mechanism seals the solder joints with glue. Step 7: After the glue is applied, the photovoltaic module is output along the main conveyor belt.

[0015] Compared with the prior art, the beneficial effects of the present invention are: 1. For the installation of junction boxes for copper (aluminum) foil assemblies, the entire process from junction box pretreatment, gluing, welding and potting has been automated. Through the collaborative design of the main water line and the parallel pretreatment subsystem, the production cycle of the entire line has been optimized, and production efficiency has been significantly improved.

[0016] 2. By acquiring images through a multi-station vision inspection system and using a PLC system module for position compensation, the positional accuracy of junction box gluing, soldering, and potting is ensured. Through multi-station online inspection, the quality control of the entire junction box installation process is improved, effectively ensuring product consistency and a high pass rate.

[0017] 3. By contacting the positive and negative output terminals of the junction box with the detection head, the operating current of the photovoltaic module under the set voltage is measured. The PLC system module calculates the output power based on the set voltage and the measured operating current, and compares it with the preset power value to determine whether the photovoltaic module power is qualified. This enables rapid verification of the photovoltaic module output power, improves detection efficiency, and ensures a high production pace. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the junction box pretreatment mechanism of the present invention; Figure 3 This is a schematic diagram of the flipping mechanism structure of the present invention; Figure 4 This is a schematic diagram of the gluing mechanism of the present invention; Figure 5 This is a schematic diagram of the soldering mechanism and welding mechanism of the present invention; Figure 6 This is a schematic diagram of the power detection and sorting mechanism of the present invention; Figure 7 This is a schematic diagram of the glue-dispensing mechanism of the present invention; Figure 8 This is a schematic diagram of the camera mounting structure of the visual inspection system of the present invention.

[0019] Figure 9 This is a schematic diagram of the production line workflow of the present invention.

[0020] In the diagram: 1. Frame; 2. Main conveyor belt; 3. Lifting mechanism; 4. Junction box pretreatment mechanism; 401. Feeding unit; 402. Junction box conveyor belt; 403. Loading unit; 404. Conveying unit; 405. Cleaning unit; 406. Glue application unit; 407. Mold; 5. Tilting mechanism; 501. First Z-axis servo module; 502. Tilting cylinder; 503. Cylinder gripper; 6. Gluing mechanism; 601. First Y-axis servo module; 602. First X-axis servo module; 603. Second Z-axis servo module; 604. First Z-axis cylinder; 605. Pneumatic gripper; 606. Probe; 7. Soldering mechanism; 701. Second Y-axis servo module; 702. Second X-axis servo module; 703. Second Z-axis cylinder; 704. Clamping component; 705. Solder paste tube; 706. Retraction component; 8. Welding mechanism; 801. Third Y-axis servo module; 802. Third X-axis servo module; 803. Third Z-axis cylinder; 804. Welding torch head; 805. Welding power supply; 9. Power detection and sorting mechanism; 901. Fourth Y-axis servo module; 902. Fourth X-axis servo module; 903. Third Z-axis servo module; 904. Fourth Z-axis cylinder; 905. Light source; 906. Detection head; 907. Suction cup; 908. Defective product conveyor belt; 10. Glue dispensing mechanism; 1001. Fifth Y-axis servo module; 1002. Fifth X-axis servo module; 1003. Fifth Z-axis cylinder; 1004. Glue gun; 11. Visual inspection system; 1101. First camera; 1102. Second camera; 1103. Third camera; 1104. Fourth camera; 1105. Fifth camera. Detailed Implementation

[0021] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0022] In the description of this application, it should be understood that if the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", "X-axis", "Y-axis", "Z-axis", etc. appear, these terms indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0023] Furthermore, where the terms "first" and "second" appear, these terms are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature.

[0024] In the description of this application, the term "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified. In this application, unless otherwise explicitly specified and limited, the terms "installed," "connected," "joined," "fixed," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly specified.

[0025] For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances. In this application, unless otherwise expressly specified and limited, the use of descriptions such as "above" or "below" the second feature indicates that the first and second features are in direct contact, or indirect contact via an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. Similarly, "below," "under," and "below" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0026] It should be noted that if an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. If an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. If so, the terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used in this application are for illustrative purposes only and do not represent the only possible implementation.

[0027] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] Please see Figures 1-8 , Figure 1This illustration shows an overall structural diagram of a junction box installation production line according to an embodiment of the present application. The junction box installation production line includes a frame 1, a PLC system module, a vision inspection system 11, two parallel main conveyor belts 2 mounted on the frame 1, and multiple lifting mechanisms 3. The two main conveyor belts 2 are used to transport photovoltaic modules. Along the conveying direction of the main conveyor belt 2, the frame 1 is sequentially equipped with a box gluing mechanism 6, a soldering mechanism 7, a welding mechanism 8, a power detection and sorting mechanism 9, and a glue dispensing mechanism 10. The frame 1 is also equipped with a junction box pretreatment mechanism 4, and a flipping mechanism 5 is provided between the unloading position of the junction box pretreatment mechanism 4 and the box gluing mechanism 6. The mounting locations of the box-gluing mechanism 6, the soldering mechanism 7, the welding mechanism 8, the power detection and sorting mechanism 9, and the glue-filling mechanism 10 correspond to the box-gluing station, the soldering station, the welding station, the power detection station, and the glue-filling station, respectively. The vision inspection system 11 includes multiple cameras set above the box-gluing station, the soldering station, the welding station, the power detection station, and the glue-filling station. The multiple cameras are used to collect position images of the photovoltaic modules and the target area of ​​the junction box. The PLC system module is connected to the vision inspection system 11, main conveyor belt 2, lifting mechanism 3, junction box pretreatment mechanism 4, flipping mechanism 5, box gluing mechanism 6, soldering mechanism 7, welding mechanism 8, power detection and sorting mechanism 9, and glue dispensing mechanism 10 via signal connection.

[0029] During operation, the photovoltaic modules are placed back-side up at the initial end of the main conveyor belt 2. As the main conveyor belt 2 moves, the photovoltaic modules sequentially pass through the gluing mechanism 6, the soldering mechanism 7, the welding mechanism 8, the power detection and sorting mechanism 9, and the glue-filling mechanism 10. Each mechanism corresponds to a workstation. Under the control of the PLC system module, the photovoltaic modules stop at each workstation for installation or testing. The entire installation device is uniformly controlled by the PLC. The PLC system module adjusts the operation of each component based on the received feedback information, realizing full automation from junction box loading to final glue-filling unloading. Furthermore, the junction box pretreatment mechanism 4 operates simultaneously with the main water line. Through the collaborative design of the main water line and the parallel pretreatment subsystem, the overall production cycle is optimized, significantly improving production efficiency.

[0030] The frame 1 is equipped with several lifting mechanisms 3. Each lifting mechanism 3 includes a lifting cylinder and a blocking block. A lifting cylinder is installed below each station, and a blocking block is installed at the top of the lifting cylinder. When the photovoltaic module flows along the main conveyor belt to a station, the PLC system module will control the lifting cylinder of the corresponding station to drive the blocking block to rise and limit the photovoltaic module.

[0031] like Figure 2As shown, the junction box pretreatment mechanism 4 includes: a feeding unit 401, a conveying unit 404, a loading unit 403, a cleaning unit 405, and a glue application unit 406; The feeding unit 401 includes a vibratory feeder and a junction box conveyor belt 402 for sorting and outputting the junction boxes; The conveying unit 404 includes a rotary table and a plurality of molds 407 arranged around the circumference of the rotary table, the plurality of molds 407 being used to support the junction box; The feeding unit 403 is used to grab the junction box from the end of the junction box conveyor belt 402 and place it in the mold 407; Cleaning unit 405 is used to perform plasma cleaning on the bonding surface of the junction box in the mold 407; The adhesive applicator 406 is used to apply adhesive to the bonding surface of the junction box in the mold 407.

[0032] The feeding unit 401 and conveying unit 404 are directly mounted on the frame 1; the loading unit 403 is mounted on the frame 1 via the first support frame, the cleaning unit 405 is mounted on the frame 1 via the first support column, and the gluing unit 406 is mounted on the frame 1 via the second support frame; the feeding unit 401 uses a vibratory feeder, and a junction box conveyor belt 402 is installed at the discharge end of the feeding unit 401; the conveying unit 404 uses a rotary table, and multiple molds 407 for carrying junction boxes are arranged circumferentially on the rotary table; the loading unit 403 is located on one side of the end of the junction box conveyor belt 402, and is used to grab the junction box from the end of the junction box conveyor belt 402 and place it in the mold 407; the conveying unit 404 carries the junction box through the cleaning unit 405 and the gluing unit 406 in sequence, and performs plasma cleaning and back adhesive dotting on the bonding surface of the junction box in the mold 407.

[0033] like Figure 4 As shown, the gluing mechanism 6 is equipped with a first Y-axis servo module 601, a first X-axis servo module 602, a first support plate, a second Z-axis servo module 603, a first Z-axis cylinder 604, a second support plate, a pneumatic gripper 605, a third support plate, a probe 606, and a third support frame. A third support frame is mounted on the frame 1. A first Y-axis servo module 601 is mounted on the third support frame. A first X-axis servo module 602 is mounted on the slider of the first Y-axis servo module 601. A second Z-axis servo module 603 is mounted on the slider of the first X-axis servo module 602. A first support plate is mounted on the slider of the second Z-axis servo module 603. A first Z-axis cylinder 604 is mounted on the first support plate. A second support plate is mounted on the output end of the first Z-axis cylinder 604. A pneumatic gripper 605 is mounted on the second support plate. A third support plate is mounted on the first support plate. A probe 606 is mounted on the third support plate.

[0034] The junction box gluing mechanism 6 is used to first conduct a continuity test by contacting the back electrode contacts of the photovoltaic module with the probe 606, and then use the pneumatic gripper 605 to grip the junction box from the cylinder gripper 503 of the flipping mechanism 5, and then glue the junction box onto the photovoltaic module; the first Y-axis servo module 601 controls the movement of the pneumatic gripper 605 and the probe 606 along the Y-axis, the first X-axis servo module 602 controls the movement of the pneumatic gripper 605 and the probe 606 along the X-axis, the second Z-axis servo module 603 controls the movement of the probe 606 along the Z-axis through the first support plate and the third support plate, and the first Z-axis cylinder 604 controls the movement of the pneumatic gripper 605 along the Z-axis through the second support plate; like Figure 3 As shown, the flipping mechanism 5 is equipped with a first Z-axis servo module 501. The first Z-axis servo module 501 is vertically mounted on the frame 1 via a second support column. A flipping cylinder 502 is mounted on the slider of the first Z-axis servo module 501. A cylinder gripper 503 is connected to the output end of the flipping cylinder 502. The cylinder gripper 503 is set with a standby position and a loading position. The standby position is located directly above the loading position of the junction box pretreatment mechanism 4. The cylinder gripper 503 picks up the pretreated junction box from the loading position of the junction box pretreatment mechanism 4 and is driven by the flipping cylinder 502 to rotate 180° in the horizontal plane to the loading position.

[0035] like Figure 5 As shown, the soldering mechanism 7 includes a second Y-axis servo module 701, a second X-axis servo module 702, a fourth support plate, a second Z-axis cylinder 703, a clamping component 704, a solder paste tube 705, and a suction component 706. The welding mechanism 8 includes a third Y-axis servo module 801, a third X-axis servo module 802, a third Z-axis cylinder 803, a welding torch head 804, and a welding power source 805.

[0036] A fourth support frame is mounted on the frame 1. A second Y-axis servo module 701 is mounted on the fourth support frame. A second X-axis servo module 702 is mounted on the slider of the second Y-axis servo module 701. A fourth support plate is mounted on the slider of the second X-axis servo module 702. A second Z-axis cylinder 703 is mounted on the fourth support plate. A clamping component 704 is mounted on the output end of the second Z-axis cylinder 703. A solder paste tube 705 is mounted on the clamping component 704. A back suction component 706 for controlling the amount of solder paste is mounted on the upper end of the solder paste tube 705.

[0037] The fourth Y-axis servo module 901 is mounted on the frame 1 via the fourth support frame. The third X-axis servo module 802 is mounted on the slider of the third Y-axis servo module 801. The fifth support plate is mounted on the slider of the third X-axis servo module 802. The third Z-axis cylinder 803 is mounted on the fifth support plate. The welding gun head 804 is mounted on the output end of the third Z-axis cylinder 803. The welding gun head 804 is powered by the welding power supply 805.

[0038] The soldering mechanism 7 is used to apply solder paste to the positive and negative electrode contacts of the photovoltaic module and the positive and negative terminals of the junction box. The clamping member 704 is used to clamp the solder paste tube 705. The suction member 706 is set on the upper end of the solder paste tube 705 and is used to control the soldering time and amount. The second Y-axis servo module 701 controls the movement of the clamping member 704 along the Y-axis direction, the second X-axis servo module 702 controls the movement of the clamping member 704 along the X-axis direction, and the second Z-axis cylinder 703 controls the movement of the solder paste tube 705 along the Z-axis direction. The welding mechanism 8 is used to weld solder joints coated with solder paste. The third Y-axis servo module 801 controls the movement of the welding gun along the Y-axis direction, the third X-axis servo module 802 controls the movement of the welding gun head 804 along the X-axis direction, and the third Z-axis cylinder 803 controls the movement of the welding gun head 804 along the Z-axis direction. The frame 1 is equipped with a welding power supply 805.

[0039] Precise and flexible drive control is achieved through servo modules and cylinders, ensuring that solder paste can be accurately applied to the required locations and that solder joints can be accurately soldered, thereby improving production quality. Welding requires more electrical energy, and a separate power supply can provide additional, stable energy for welding, ensuring welding quality.

[0040] like Figure 6 As shown, the power detection and sorting mechanism 9 includes a drive element, a light source 905, a detection head 906, a suction cup 907, and a defective product conveyor belt 908. The drive element includes a fourth Y-axis servo module 901, a sixth support plate, a third Z-axis servo module 903, a fourth Z-axis cylinder 904, a seventh support plate, an eighth support plate, and a fourth X-axis servo module 902. The light source 905 is located below the power detection station and is used to provide simulated illumination for the photovoltaic modules. The detection head 906 is connected to and installed at the output end of the fourth Z-axis cylinder 904 and is used to make electrical contact with the positive and negative output terminals of the junction box for power detection. The suction cup 907 is connected to and installed on the slider of the third Z-axis servo module 903 and is used to adsorb defective products. The defective product conveyor belt 908 is installed on one side of the frame 1, and the conveying direction of the defective product conveyor belt 908 is parallel to the installation direction of the fourth Y-axis servo module 901, and is used to convey defective products.

[0041] A fifth support frame is mounted on the frame 1. A fourth Y-axis servo module 901 is mounted on the fifth support frame. A fourth X-axis servo module 902 is mounted on the slider of the fourth Y-axis servo module 901. A third Z-axis servo module 903 is mounted on the slider of the fourth X-axis servo module 902. A sixth support plate is mounted on the slider of the third Z-axis servo module 903. A seventh support plate is mounted on the sixth support plate. A fourth Z-axis cylinder 904 and a suction cup 907 are mounted on the seventh support plate. An eighth support plate is mounted on the output end of the fourth Z-axis cylinder 904. A detection head 906 is mounted on the eighth support plate.

[0042] The power detection and sorting mechanism 9 is used to detect the power of the welded photovoltaic modules and reject defective products. When the photovoltaic modules are conveyed to the light source 905 by the main conveyor belt 2, the light-receiving surface of the photovoltaic modules works normally under illumination. The detection head 906 contacts the positive and negative output terminals of the junction box to measure the operating current of the photovoltaic modules under the set voltage. The PLC system module calculates the output power based on the set voltage and the measured operating current, and compares it with the preset power value to determine whether it is qualified. For qualified products, they continue to move along the main conveyor belt 2 to the next... In the process, for defective products, the PLC system module controls the suction cup 907 to pick up the defective products and place them on the defective product conveyor belt 908 for output; the fourth Y-axis servo module 901 controls the movement of the suction cup 907 and the detection head 906 along the Y-axis direction, the fourth X-axis servo module 902 controls the movement of the suction cup 907 and the detection head 906 along the X-axis direction, the third Z-axis servo module 903 controls the movement of the suction cup 907 along the Z-axis direction through the sixth and seventh support plates, and the fourth Z-axis cylinder 904 controls the movement of the detection head 906 along the Z-axis direction through the eighth support plate; The servo module and cylinder enable precise and flexible drive control, ensuring that the detection head 906 can establish stable and reliable electrical contact with the positive and negative output terminals of the junction box, thus ensuring the accuracy of the detection results. At the same time, it controls the suction cup 907 to pick up and unload defective products when needed. The suction cup 907 shares the fifth support frame and the drive components of the fourth Y-axis servo module 901, the fourth X-axis servo module 902, and the third Z-axis servo module 903 with the detection head 906, which helps to simplify the size of the equipment and reduce manufacturing costs.

[0043] like Figure 5 As shown, the glue dispensing mechanism 10 includes a fifth Y-axis servo module 1001, a fifth X-axis servo module 1002, a ninth support plate, a fifth Z-axis cylinder 1003, a tenth support plate, a glue gun 1004, a glue storage tank, and a sixth support frame. A sixth support frame is mounted on frame 1. A fifth Y-axis servo module 1001 is mounted on the sixth support frame. A fifth X-axis servo module 1002 is mounted on the slider of the fifth Y-axis servo module 1001. A ninth support plate is mounted on the slider of the fifth X-axis servo module 1002. A fifth Z-axis cylinder 1003 is mounted on the ninth support plate. A tenth support plate is mounted on the output end of the fifth Z-axis cylinder 1003. A glue gun 1004 is mounted on the tenth support plate. The glue gun 1004 is connected to a glue storage tank via a glue delivery pipe, and a solenoid valve for controlling the glue path is installed on the glue delivery pipe.

[0044] The glue-dispensing mechanism 10 is used to dispense glue and seal the weld points of qualified products; the fifth Y-axis servo module 1001 controls the movement of the glue gun 1004 along the Y-axis, the fifth X-axis servo module 1002 controls the movement of the glue gun 1004 along the X-axis, the fifth Z-axis cylinder 1003 controls the movement of the glue gun 1004 along the Z-axis, and the solenoid valve controls the glue dispensing volume and dispensing time of the glue gun 1004; the drive composed of the servo module and the cylinder achieves precise and flexible drive control, ensuring that the weld points can be accurately sealed during glue dispensing and sealing, and ensuring the sealing quality.

[0045] The vision inspection system includes multiple cameras positioned above the gluing station, soldering station, welding station, power detection station, and potting station. The cameras are used to capture positional images of the target area of ​​the photovoltaic module and upload them to the PLC system module.

[0046] like Figure 3 As shown, specifically, the vision inspection system 11 includes a first camera 1101, a second camera 1102, a third camera 1103, a fourth camera 1104, and a fifth camera 1105. The first camera 1101 is located above the gluing station and is used to capture position images of the electrode contacts on the backsheet of the photovoltaic module and upload them to the PLC system module. The second camera 1102 is located above the soldering station and is used to capture position images inside the junction box and upload them to the PLC system module. The third camera 1103 is located above the soldering station and is used to capture position images inside the junction box and upload them to the PLC system module. The fourth camera 1104 is located above the power detection station and is used to capture position images inside the junction box and upload them to the PLC system module. The fifth camera 1105 is located above the potting station and is used to capture position images inside the junction box and upload them to the PLC system module.

[0047] The PLC system module performs appearance inspection, position detection, and position compensation calculation based on the position images uploaded by each camera, generates corresponding position compensation parameters, and issues motion commands to each mechanism to ensure the accuracy of the processing position of each process and the consistency of the product.

[0048] As shown in the figure, the installation method of the junction box installation production line of the present invention is as follows: Step 1: Place the photovoltaic modules on the feeding end of the main conveyor belt 2, while the junction box pretreatment mechanism 4 feeds, cleans, and applies glue to the junction boxes. Step 2: The photovoltaic module is transported to the gluing station and positioned. The vision inspection system collects the position images of the electrode contacts on the back panel of the photovoltaic module. The PLC system module performs appearance inspection and positioning. The probe 606 of the gluing mechanism 6 contacts the photovoltaic module to perform a continuity test. The pneumatic gripper 605 of the gluing mechanism 6 takes the flipped junction box from the cylinder gripper 503 of the flipping mechanism 5 and glues it to the back panel of the photovoltaic module. Step 3: The photovoltaic module is transported to the soldering station and positioned. The vision inspection system collects the position image inside the junction box. The PLC system module performs appearance inspection and positions the solder joints. The soldering mechanism 7 controls the amount of solder paste used by the suction component 706 to apply solder paste to the solder joints inside the junction box. Step 4: The photovoltaic modules are transported to the welding station and positioned. The vision inspection system collects the position image inside the junction box. The PLC system module performs appearance inspection and positions the weld points. The welding gun head 804 of the welding mechanism 8 welds the weld points under power supply. Step 5: The photovoltaic modules are transported to the power detection station and positioned. The vision inspection system captures the position image inside the junction box. The PLC system module performs appearance inspection and positioning. The detection head 906 of the power detection and sorting mechanism contacts the positive and negative output terminals of the junction box to measure the operating current of the photovoltaic modules under the set voltage. The PLC system module calculates the output power based on the set voltage and the measured operating current, and compares it with the preset power value to determine whether it is qualified. The suction cup 907 of the power detection and sorting mechanism picks up the unqualified products and transfers them to the unqualified product conveyor belt 908 for sorting. Step 6: The photovoltaic module is transported to the glue-filling station and positioned. The vision inspection system collects the position image inside the junction box. The PLC system module performs appearance inspection and positioning. The glue gun 1004 of the glue-filling mechanism 10 fills and seals the solder joints under the control of the solenoid valve. Step 7: After the glue is applied, the photovoltaic modules are output along the main conveyor belt 2.

[0049] Working principle of the invention: When installing the junction box, it relies on the PLC system. Unified coordination of modules and visual inspection system The real-time feedback image data is as follows: When the photovoltaic module is transported to the gluing mechanism 6 and stops, the first camera 1101 at the gluing station acquires an image and transmits it back to the PLC system module. The PLC system module performs appearance inspection and backplane electrode contact position compensation calculation based on the image. If the appearance inspection is qualified, the PLC system module sends a motion command to the gluing mechanism 6 to perform the gluing operation. If the appearance inspection is unqualified, the PLC system module will send a command to the lifting mechanism 3 at the gluing station to transfer the unqualified product to the soldering station.

[0050] When the product is delivered to the soldering station, the second camera 1102 at the soldering station will capture the position image inside the junction box and transmit it back to the PLC system module. The PLC system module will perform appearance position detection and backplate electrode contact position compensation calculation based on the image to determine whether the box is qualified. If qualified, the PLC system module will issue a motion command to the soldering mechanism 7 to perform the soldering operation. If unqualified, the PLC system module will issue a transfer command to the lifting mechanism 3 at the soldering station to transfer the photovoltaic module to the welding station.

[0051] When the product is delivered to the welding station, the third camera 1103 at the welding station will capture the position image inside the junction box and transmit it back to the PLC system module. The PLC system module will perform appearance position detection and back plate electrode contact position compensation calculation based on the image to determine whether the soldering is qualified. If qualified, the PLC system module will issue a motion command to the welding mechanism 8 to perform the welding operation. If unqualified, the PLC system module will issue a transfer command to the lifting mechanism 3 at the welding station to transfer the photovoltaic module to the power detection station.

[0052] When the product is delivered to the power testing station, the fourth camera 1104 at the power testing station will capture the position image inside the junction box and transmit it back to the PLC system module. The PLC system module performs appearance position detection and backplate electrode contact position compensation calculation based on the image to determine whether the welding quality is qualified. If qualified, the PLC system module sends a motion command to the power testing and sorting mechanism 9 to perform the power testing operation. If the welding quality, appearance, box adhesion, or soldering is unqualified, the PLC system module sends a command to the power testing and sorting mechanism 9 to remove the photovoltaic module as a defective product through the suction cup 907. If the power testing is unqualified, the PLC system module sends a command to the power testing and sorting mechanism 9 to remove the photovoltaic module as a defective product through the suction cup 907.

[0053] When the product is delivered to the glue-filling station, the fifth camera 1105 at the glue-filling station will capture the position image inside the junction box and transmit it back to the PLC system module. The PLC system module performs appearance position detection and back panel electrode contact position compensation calculation based on the image. The PLC system module sends motion commands to the glue-filling mechanism 10 to perform the glue-filling operation, driving the glue gun 1004 to fill the welding points of the photovoltaic module with glue.

[0054] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A junction box installation production line, characterized in that: The junction box installation production line includes a frame (1), a PLC system module, a vision inspection system (11), two parallel main conveyor belts (2) and multiple lifting mechanisms (3) set on the frame (1). The two main conveyor belts (2) are used to transport photovoltaic modules. The frame (1) is provided with a box gluing mechanism (6), a soldering mechanism (7), a welding mechanism (8), a power detection and sorting mechanism (9), and a glue dispensing mechanism (10) in sequence across the conveying direction of the main conveyor belt (2). The frame (1) is also provided with a junction box pretreatment mechanism (4), and a flipping mechanism (5) is provided between the unloading position of the junction box pretreatment mechanism (4) and the gluing mechanism (6). The mounting locations of the box gluing mechanism (6), the soldering mechanism (7), the welding mechanism (8), the power detection and sorting mechanism (9), and the glue-filling mechanism (10) correspond to the box gluing station, the soldering station, the welding station, the power detection station, and the glue-filling station, respectively. The vision inspection system (11) includes multiple cameras set above the box gluing station, the soldering station, the welding station, the power detection station, and the glue-filling station. The multiple cameras are used to collect position images of the photovoltaic module and the target area of ​​the junction box. The PLC system module is connected to the vision inspection system (11), the main conveyor belt (2), the lifting mechanism (3), the junction box pretreatment mechanism (4), the flipping mechanism (5), the box gluing mechanism (6), the soldering mechanism (7), the welding mechanism (8), the power detection and sorting mechanism (9), and the glue-pouring mechanism (10) via signals. The gluing mechanism (6) is equipped with a first Y-axis servo module (601), a first X-axis servo module (602), a second Z-axis servo module (603), and a first Z-axis cylinder (604). The first Z-axis cylinder (604) is connected and installed on the slider of the second Z-axis servo module (603). A pneumatic gripper (605) is connected and installed at the output end of the first Z-axis cylinder (604). A probe (606) is also connected and installed on the slider of the second Z-axis servo module (603). The pneumatic gripper (605) is used to grip the junction box from the cylinder gripper (503), and the probe (606) is used to contact the back electrode contacts of the photovoltaic module for a continuity test. The power detection and sorting mechanism (9) includes a drive element, a light source (905), a detection head (906), a suction cup (907), and a defective product conveyor belt (908). The drive components include a fourth Y-axis servo module (901), a fourth X-axis servo module (902), a third Z-axis servo module (903), and a fourth Z-axis cylinder (904). The light source (905) is positioned below the power detection station to provide simulated illumination for the photovoltaic module; The detection head (906) is connected to the output end of the fourth Z-axis cylinder (904) and is used to make electrical contact with the positive and negative output ends of the junction box for power detection. The suction cup (907) is connected to the slider of the third Z-axis servo module (903) and is used to adsorb defective products; The non-conforming product conveyor belt (908) is installed on one side of the frame (1) for conveying non-conforming products.

2. The junction box installation production line according to claim 1, characterized in that: The junction box pretreatment mechanism (4) includes: a feeding unit (401), a conveying unit (404), a loading unit (403), a cleaning unit (405), and a glue application unit (406). The feeding unit (401) includes a vibratory feeder and a junction box conveyor belt (402) for sorting and outputting the junction boxes; The conveying unit (404) includes a rotary table and a plurality of molds (407) arranged around the rotary table, the plurality of molds (407) being used to carry the junction box; The feeding unit (403) is used to grab the junction box from the end of the junction box conveyor belt (402) and place it in the mold (407); The cleaning unit (405) is used to perform plasma cleaning on the bonding surface of the junction box in the mold (407); The glue application unit (406) is used to apply adhesive to the bonding surface of the junction box in the mold (407).

3. The junction box installation production line according to claim 1, characterized in that: The flipping mechanism (5) is provided with a first Z-axis servo module (501). The first Z-axis servo module (501) is vertically connected and installed on the frame (1). A flipping cylinder (502) is installed on the slider of the first Z-axis servo module (501). A cylinder gripper (503) is connected to the output end of the flipping cylinder (502). The cylinder gripper (503) is used to grip the pre-processed junction box from the unloading position of the junction box pre-processing mechanism (4) and is driven by the flipping cylinder (502) to rotate 180° in the horizontal plane.

4. The junction box installation production line according to claim 1, characterized in that: The soldering mechanism (7) is equipped with a second Y-axis servo module (701), a second X-axis servo module (702), and a second Z-axis cylinder (703). The second Z-axis cylinder (703) is connected to a clamping member (704), which clamps a solder paste tube (705). The upper end of the solder paste tube (705) is equipped with a back suction member (706) for controlling the amount of solder paste used.

5. The junction box installation production line according to claim 1, characterized in that: The welding mechanism (8) includes a third Y-axis servo module (801), a third X-axis servo module (802), and a third Z-axis cylinder (803). The output end of the third Z-axis cylinder (803) is equipped with a welding gun head (804). A welding power supply (805) is provided on the frame (1). The welding gun head (804) is powered by the welding power supply (805).

6. The junction box installation production line according to claim 1, characterized in that: The glue dispensing mechanism (10) is equipped with a fifth Y-axis servo module (1001), a fifth X-axis servo module (1002), a fifth Z-axis cylinder (1003), and a glue storage tank. The output end of the fifth Z-axis cylinder (1003) is connected to a glue gun (1004). The glue gun (1004) is connected to the glue storage tank through a glue delivery pipe, and a solenoid valve for controlling the glue path is provided on the glue delivery pipe.

7. The junction box installation production line according to claim 1, characterized in that: The visual inspection system (11) includes a first camera (1101), a second camera (1102), a third camera (1103), a fourth camera (1104), and a fifth camera (1105). The first camera (1101) is located above the gluing station and is used to collect position images of the back electrode contacts of the photovoltaic module and upload them to the PLC system module. The second camera (1102) is located above the soldering station and is used to capture position images inside the junction box and upload them to the PLC system module. The third camera (1103) is located above the welding station and is used to collect position images inside the junction box and upload them to the PLC system module. The fourth camera (1104) is located above the power detection station and is used to collect position images inside the junction box and upload them to the PLC system module. The fifth camera (1105) is located above the glue-filling station and is used to collect position images inside the junction box and upload them to the PLC system module.

8. The installation method of a junction box installation production line according to any one of claims 1-7, characterized in that: Step 1: Place the photovoltaic module on the feeding end of the main conveyor belt (2), and at the same time, the junction box pretreatment mechanism (4) feeds, cleans and applies glue to the junction box; Step 2: The photovoltaic module is transported to the gluing station and positioned. The vision inspection system (11) collects the position image of the electrode contact of the back panel of the photovoltaic module. The PLC system module performs appearance inspection and positioning. The gluing mechanism (6) performs a continuity test on the photovoltaic module contact. The gluing mechanism (6) takes the flipped and pre-processed junction box from the flipping mechanism (5) and glues it to the back panel of the photovoltaic module. Step 3: The photovoltaic module is transported to the soldering station and positioned. The vision inspection system (11) collects the position image inside the junction box. The PLC system module performs appearance inspection and solder joint positioning. The soldering mechanism (7) applies solder paste to the solder joints inside the junction box. Step 4: The photovoltaic module is transported to the welding station and positioned. The visual inspection system (11) collects the position image inside the junction box. The PLC system module performs appearance inspection and weld point positioning. The welding mechanism (8) welds the weld points. Step 5: The photovoltaic module is transported to the power detection station and positioned. The vision inspection system (11) collects the position image inside the junction box. The PLC system module performs appearance inspection and positioning. The power detection and sorting mechanism (9) measures the working current of the photovoltaic module under the set voltage. The PLC system module calculates the output power based on the set voltage and the measured working current, and compares it with the preset power value to determine whether it is qualified. The power detection and sorting mechanism (9) sorts the unqualified products. Step 6: The photovoltaic module is transported to the glue-filling station and positioned. The vision inspection system (11) collects the position image inside the junction box. The PLC system module performs appearance inspection and positioning. The glue-filling mechanism (10) seals the solder joints with glue. Step 7: After the potting is completed, the photovoltaic module is output along the main conveyor belt (2).

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