Wire box dismantling equipment and wire box dismantling method for recycling waste photovoltaic module

Abstract

The invention discloses wire box dismantling equipment and a wire box dismantling method for waste photovoltaic module recycling. The wire box dismantling equipment comprises a six-axis robot, a wire box dismantling device is arranged at the working end of the six-axis robot, a working table is arranged in front of the working face of the six-axis robot, and a visual recognition device is arranged above the working table. The dismantling method comprises the steps that 1, centering, positioning and limiting are conducted after feeding; 2, visually identifying the model and the position and size of the wire box; 3, the wire box is dismantled by the wire box dismantling device; and 4, discharging is conducted, specifically, the workpiece is conveyed to the next working procedure. The problems of low efficiency and poor adaptability of traditional manual wire box dismounting are solved.

Description

Technical Field

[0001] This invention belongs to the field of waste photovoltaic module recycling technology, specifically relating to junction box removal equipment for waste photovoltaic module recycling, and also to a method for removing the junction box. Background Technology

[0002] Solar photovoltaic (PV) modules are devices that convert solar energy into electrical energy. PV modules have a lifespan of 20-30 years. After dismantling retired and scrapped solar PV modules, the secondary utilization of PV module materials has broad market prospects. Not only do the aluminum frames, glass, and solder strips in discarded PV modules have recycling value, but the junction boxes and internal cables also contain recyclable resources such as copper and plastics. Efficiently dismantling junction boxes is a key step in improving recycling efficiency. Currently, junction box removal mainly relies on manual labor or simple mechanical operations, which presents numerous technical bottlenecks and makes it difficult to meet the needs of large-scale recycling: ① Low efficiency and high cost: Manual removal relies on worker experience, and removing a single module's junction box typically takes more than 30 seconds. Long-term repetitive work easily leads to fatigue, and labor costs account for more than 40% of the total recycling cost, making it unsuitable for large-scale recycling production lines; ② Poor removal consistency and high resource loss: Manual operation makes it difficult to precisely control the force and angle, easily causing damage to the junction box, cracks in the photovoltaic substrate, or damage to the backsheet, resulting in reduced recycling resource utilization. Some modules cannot be reused due to damage, with a loss rate of 15%-20%; ③ Insufficient adaptability and difficulty in replacement: The position, size, and fixing method (adhesive or clip) of junction boxes for photovoltaic modules from different manufacturers and models vary significantly. Traditional mechanical tools require manual adjustment of positioning devices (such as photoelectric switches and baffles), and replacement time typically exceeds 30 seconds. Minutes, seriously affecting the continuity of the production line; ④ Safety and environmental hazards: during manual dismantling, improper tool operation may cause safety accidents such as glass splashing, and simple machinery has no dust collection function, and the cleaning of adhesive residue can easily cause environmental pollution.

[0003] With the large-scale development of the photovoltaic recycling industry, enterprises have an increasingly urgent need for automation, high precision, and high compatibility in the junction box removal process. While some simple mechanical devices in existing technologies attempt to achieve semi-automation, they suffer from low positioning accuracy (above ±2mm), compatibility only with a single junction box model, and easy damage to modules. Therefore, developing robotic junction box removal equipment and methods with high-precision positioning, multi-model compatibility, and low damage rate has become a key direction for breaking through the bottleneck of efficient photovoltaic module recycling and an important support for promoting the industry's transformation from labor-intensive to technology-intensive. Summary of the Invention

[0004] The purpose of this invention is to provide a junction box removal device for recycling waste photovoltaic modules, which solves the problems of low efficiency and poor adaptability of traditional manual junction box removal.

[0005] Another objective of this invention is to provide a method for removing junction boxes for recycling waste photovoltaic modules.

[0006] The technical solution adopted in this invention includes a six-axis robot, a wire box removal device at the working end of the six-axis robot, a worktable in front of the working end of the six-axis robot, and a visual recognition device above the worktable.

[0007] The invention is further characterized by: The junction box removal device includes a mounting frame, a first drive motor is installed on the side of the mounting frame, two slide rails are opened on the frame of the mounting frame, a movable frame is slidably installed on the slide rails, a second shovel plate is installed on the bottom plate of the movable frame, the first shovel plate is installed on the bottom of the mounting frame near the first drive motor, and the output end of the first drive motor is connected to the movable frame.

[0008] The workbench is equipped with a conveyor belt, and a second drive motor is installed on the side of the workbench. A positioning device is also installed on the workbench. The positioning device includes a pair of positioning frames, which are located in the middle of both sides of the conveyor belt. The positioning frames are slidably mounted on the guide rail of the positioning device. A positioning cylinder is installed in the middle of the guide rail, and the two output ends of the positioning cylinder are connected to the two positioning frames.

[0009] The visual recognition device includes a support frame with several cameras mounted on the top edge of the support frame, and the cameras are located directly above the workbench.

[0010] The positioning frame has a C-shaped side and several auxiliary wheels are set along its edge.

[0011] Another technical solution adopted in this invention is implemented according to the following steps: Step 1: After loading the material, perform centering, positioning, and limiting. Step 2: Visually identify the model, junction box location, and dimensions; Step 3: The junction box removal device is used to remove the junction box; Step 4: Unload the workpiece and transport it to the next process.

[0012] Another feature of the present invention is that: Step 1 specifically involves the workpiece being transported from the previous process to the workbench, the conveyor belt transporting the workpiece to the working position, the positioning cylinder being activated, and the positioning frame being driven to center, position, and limit the workpiece on both sides.

[0013] Step 2 specifically involves the camera in the vision recognition device identifying the workpiece, confirming the component model of the workpiece, identifying the position of the wire box, identifying the size of the wire box, and transmitting the identified information to the six-axis robot.

[0014] Step 3 is as follows: the six-axis robot moves the wire box removal device above the wire box based on the information recognized by the camera. Based on the wire box size and position information given by the visual recognition device, the robot controls the distance between the second shovel and the first shovel. The six-axis robot then places the first and second shovels of the wire box removal device against the two sides of the wire box. The first drive motor controls the second shovel to move closer to the first shovel and shovel the wire box off to complete the removal of the wire box.

[0015] Step 4 is as follows: the six-axis robot drives the wire box removal device to place the removed wire box in the designated position, then the positioning cylinder returns to its original position, the positioning frame cancels the positioning and limit of the workpiece, the second drive motor starts, and the conveyor belt sends the workpiece along the conveyor line to the next process.

[0016] The beneficial effects of this invention are: 1. The equipment adopts a universal design, which can support the removal of different models and specifications of junction boxes according to different photovoltaic modules, thereby improving the flexibility and continuity of the production line.

[0017] 2. Equipped with an intelligent control system and a visual positioning system, it can automatically confirm and identify the number, location and size of the photovoltaic module junction boxes, and monitor the actions during the dismantling process in real time to avoid damage to the modules due to improper operation and ensure maximum resource recovery rate.

[0018] 3. The mechanism is reasonably designed, and the removal cycle of a single component junction box is controlled within 60 seconds. After removal, there are no cable residues on the surface of the component, and the positioning accuracy is high, ensuring the overall work efficiency.

[0019] 4. The overall structure is compact and occupies a small area, making it easy to integrate into existing recycling production lines while reducing equipment installation and maintenance costs. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of the junction box removal equipment for recycling waste photovoltaic modules according to the present invention; Figure 2 This is a side view of the junction box removal device for recycling waste photovoltaic modules according to the present invention; Figure 3 This is a schematic diagram of the overall structure of the junction box removal device of the present invention; Figure 4 This is a process flow diagram of the dismantling method of the junction box dismantling equipment for recycling waste photovoltaic modules according to the present invention.

[0021] In the diagram, 1 is a six-axis robot; 101 is a junction box removal device; 1011 is a first drive motor; 1012 is a first shovel; 1013 is a second shovel; 1014 is a slide rail; 1015 is a mounting frame; and 1016 is a moving frame. Workbench; 201, Conveyor belt; 2011, Second drive motor; 202, Positioning device; 2021, Positioning frame; 2022, Guide rail; 2023, Positioning cylinder; Visual recognition device; 301, camera; 302, support frame. Detailed Implementation

[0022] The following detailed description is provided in conjunction with specific implementation methods. Example

[0023] refer to Figure 1-3 As shown, the present invention provides a junction box removal device for recycling waste photovoltaic modules, comprising a six-axis robot 1. A junction box removal device 101 is installed at the working end of the six-axis robot 1. A worktable 2 is placed in front of the working front of the six-axis robot 1. Waste photovoltaic modules are transported to the worktable 2 via a conveyor belt 201, with the side containing the junction box facing upwards so that the junction box removal device 101 can remove the junction box. A vision recognition device 3 is placed above the worktable 2, which can identify the model of the waste photovoltaic module, the size of the junction box, and the position of the junction box, and transmit the identified information to the six-axis robot 1. The six-axis robot 1 can then perform the removal operation based on the identified information. Example

[0024] refer to Figure 1-3 As shown, the present invention provides a junction box removal device for recycling waste photovoltaic modules, comprising a six-axis robot 1. A junction box removal device 101 is installed at the working end of the six-axis robot 1. A worktable 2 is placed in front of the working front of the six-axis robot 1. Waste photovoltaic modules are transported to the worktable 2 via a conveyor belt 201, with the side containing the junction box facing upwards so that the junction box removal device 101 can remove the junction box. A vision recognition device 3 is placed above the worktable 2, which can identify the model of the waste photovoltaic module, the size of the junction box, and the position of the junction box, and transmit the identified information to the six-axis robot 1. The six-axis robot 1 can then perform the removal operation based on the identified information.

[0025] Specifically, the junction box removal device 101 includes a mounting frame 1015. The top of the mounting frame 1015 is bolted to the working end of the six-axis robot 1. A first drive motor 1011 is mounted on the side of the mounting frame 1015. The first drive motor 1011 is connected to the control system of the six-axis robot 1. Two slide rails 1014 are provided on the frame of the mounting frame 1015 for mounting a movable frame 1016. The output end of the first drive motor 1011 is connected to the side of the movable frame 1016. The first drive motor 1011 can drive the movable frame 1016 to slide on the slide rails 1014. A second shovel plate 1013 is fixedly connected to the bottom of the movable frame 1016. A first shovel plate 1012 is fixedly connected to the bottom of the mounting frame 1015 near the bottom of the first drive motor 1011. By moving the second shovel plate 1013, a shearing force is formed with the first shovel plate 1012, which can remove the junction box. Example

[0026] refer to Figure 1-3 As shown, the present invention provides a junction box removal device for recycling waste photovoltaic modules, comprising a six-axis robot 1. A junction box removal device 101 is installed at the working end of the six-axis robot 1. A worktable 2 is placed in front of the working front of the six-axis robot 1. Waste photovoltaic modules are transported to the worktable 2 via a conveyor belt 201, with the side containing the junction box facing upwards so that the junction box removal device 101 can remove the junction box. A vision recognition device 3 is placed above the worktable 2, which can identify the model of the waste photovoltaic module, the size of the junction box, and the position of the junction box, and transmit the identified information to the six-axis robot 1. The six-axis robot 1 can then perform the removal operation based on the identified information.

[0027] Specifically, the junction box removal device 101 includes a mounting frame 1015. The top of the mounting frame 1015 is bolted to the working end of the six-axis robot 1. A first drive motor 1011 is mounted on the side of the mounting frame 1015. The first drive motor 1011 is connected to the control system of the six-axis robot 1. Two slide rails 1014 are provided on the frame of the mounting frame 1015 for mounting a movable frame 1016. The output end of the first drive motor 1011 is connected to the side of the movable frame 1016. The first drive motor 1011 can drive the movable frame 1016 to slide on the slide rails 1014. A second shovel plate 1013 is fixedly connected to the bottom of the movable frame 1016. A first shovel plate 1012 is fixedly connected to the bottom of the mounting frame 1015 near the bottom of the first drive motor 1011. By moving the second shovel plate 1013, a shearing force is formed with the first shovel plate 1012, which can remove the junction box.

[0028] Specifically, a conveyor belt 201 is installed on the surface of the workbench 2, and a second drive motor 2011 is installed on the side of the workbench 2. The second drive motor 2011 drives the conveyor belt 201 to rotate. A positioning device 202 is installed under the surface of the workbench 2. The positioning device 202 includes a guide rail 2022 and a pair of positioning frames 2021 installed on the guide rail 2022. The two positioning frames 2021 are located on both sides of the middle of the conveyor belt 201. A positioning cylinder 2023 is installed in the middle of the guide rail 2022. The two positioning frames 2021 are driven by connecting the two output ends of the positioning cylinder 2023. When the two positioning frames 2021 are close to each other, they can clamp, position and limit the waste photovoltaic modules located on the conveyor belt 201.

[0029] The positioning frame 2021 has a C-shaped side to accommodate the side of the conveyor belt 201, enabling it to clamp, position, and limit waste photovoltaic modules of a certain size. Four auxiliary wheels are installed along the edges of each of the two positioning frames 2021. When the two positioning frames 2021 clamp the waste photovoltaic modules, the auxiliary wheels abut against the edges of the modules. Example

[0030] refer to Figure 1-3 As shown, the present invention provides a junction box removal device for recycling waste photovoltaic modules, comprising a six-axis robot 1. A junction box removal device 101 is installed at the working end of the six-axis robot 1. A worktable 2 is placed in front of the working front of the six-axis robot 1. Waste photovoltaic modules are transported to the worktable 2 via a conveyor belt 201, with the side containing the junction box facing upwards so that the junction box removal device 101 can remove the junction box. A vision recognition device 3 is placed above the worktable 2, which can identify the model of the waste photovoltaic module, the size of the junction box, and the position of the junction box, and transmit the identified information to the six-axis robot 1. The six-axis robot 1 can then perform the removal operation based on the identified information.

[0031] Specifically, the junction box removal device 101 includes a mounting frame 1015. The top of the mounting frame 1015 is bolted to the working end of the six-axis robot 1. A first drive motor 1011 is mounted on the side of the mounting frame 1015. The first drive motor 1011 is connected to the control system of the six-axis robot 1. Two slide rails 1014 are provided on the frame of the mounting frame 1015 for mounting a movable frame 1016. The output end of the first drive motor 1011 is connected to the side of the movable frame 1016. The first drive motor 1011 can drive the movable frame 1016 to slide on the slide rails 1014. A second shovel plate 1013 is fixedly connected to the bottom of the movable frame 1016. A first shovel plate 1012 is fixedly connected to the bottom of the mounting frame 1015 near the bottom of the first drive motor 1011. By moving the second shovel plate 1013, a shearing force is formed with the first shovel plate 1012, which can remove the junction box.

[0032] Specifically, a conveyor belt 201 is installed on the surface of the workbench 2, and a second drive motor 2011 is installed on the side of the workbench 2. The second drive motor 2011 drives the conveyor belt 201 to rotate. A positioning device 202 is installed under the surface of the workbench 2. The positioning device 202 includes a guide rail 2022 and a pair of positioning frames 2021 installed on the guide rail 2022. The two positioning frames 2021 are located on both sides of the middle of the conveyor belt 201. A positioning cylinder 2023 is installed in the middle of the guide rail 2022. The two positioning frames 2021 are driven by connecting the two output ends of the positioning cylinder 2023. When the two positioning frames 2021 are close to each other, they can clamp, position and limit the waste photovoltaic modules located on the conveyor belt 201.

[0033] The positioning frame 2021 has a C-shaped side to accommodate the side of the conveyor belt 201, enabling it to clamp, position, and limit waste photovoltaic modules of a certain size. Four auxiliary wheels are installed along the edges of each of the two positioning frames 2021. When the two positioning frames 2021 clamp the waste photovoltaic modules, the auxiliary wheels abut against the edges of the modules.

[0034] Specifically, the visual recognition device 3 includes a support frame 302, with three cameras 301 mounted on the top edge of the support frame 302. The three cameras 301 are located directly above the workbench 2. The recognition information from the cameras 301 can be transmitted to the control system of the six-axis robot 1. The six-axis robot 1 removes the wire box according to the identified wire box size, wire box location, and waste photovoltaic module model. Example

[0035] refer to Figure 4 As shown, the method for removing junction boxes used in the recycling of waste photovoltaic modules is implemented according to the following steps: Step 1: After loading the material, perform centering, positioning, and limiting. Step 2: Visually identify the model, junction box location, and dimensions; Step 3: The junction box removal device 101 removes the junction box; Step 4: Unload the workpiece and transport it to the next process. Example

[0036] Compared to Example 5, the specific steps of the junction box removal method for recycling waste photovoltaic modules in this embodiment are as follows: Step 1 is as follows: the workpiece is transported from the previous process to the workbench 2, the conveyor belt 201 transports the workpiece to the working position, the positioning cylinder 2023 is started, and the positioning frame 2021 is driven to center, position and limit the workpiece on both sides. Step 2 specifically involves the camera 301 in the visual recognition device 3 recognizing the workpiece, confirming the component model of the workpiece, recognizing the position of the wire box, recognizing the size of the wire box, and transmitting the recognized information to the six-axis robot 1. Step 3 is as follows: the six-axis robot 1 moves the wire box removal device 101 to the top of the wire box according to the information identified by the camera 301. According to the wire box size information and wire box position information given by the vision recognition device 3, the robot 1 controls the distance between the second shovel 1013 and the first shovel 1012. The six-axis robot 1 brings the first shovel 1012 and the second shovel 1013 of the wire box removal device 101 against the two sides of the wire box. The first drive motor 1011 controls the second shovel 1013 to move closer to the first shovel 1012 to shovel off the wire box and complete the removal of the wire box. Step 4 is as follows: the six-axis robot 1 drives the wire box removal device 101 to place the removed wire box in the designated position. Then the positioning cylinder 2023 returns to its original position, and the two positioning frames 2021 move away from each other to cancel the positioning and limiting of the workpiece. The second drive motor 2011 starts, and the conveyor belt 201 sends the workpiece along the conveyor line to the next process.

Claims

1. A junction box removal device for recycling waste photovoltaic modules, characterized in that, The system includes a six-axis robot (1), with a wire box removal device (101) installed at the working end of the six-axis robot (1), a worktable (2) installed in front of the working face of the six-axis robot (1), and a visual recognition device (3) installed above the worktable (2).

2. The junction box removal equipment for recycling waste photovoltaic modules according to claim 1, characterized in that, The junction box removal device (101) includes a mounting frame (1015), a first drive motor (1011) is provided on the side of the mounting frame (1015), two slide rails (1014) are provided on the frame of the mounting frame (1015), a movable frame (1016) is slidably provided on the slide rails (1014), a second shovel plate (1013) is provided at the bottom of the movable frame (1016), a first shovel plate (1012) is provided at the bottom of the mounting frame (1015) near the first drive motor (1011), and the output end of the first drive motor (1011) is connected to the movable frame (1016).

3. The junction box removal equipment for recycling waste photovoltaic modules according to claim 1, characterized in that, The workbench (2) is equipped with a conveyor belt (201), and a second drive motor (2011) is provided on the side of the workbench (2). A positioning device (202) is also provided on the workbench (2). The positioning device (202) includes a pair of positioning frames (2021). The pair of positioning frames (2021) are located in the middle of both sides of the conveyor belt (201). The positioning frames (2021) are slidably mounted on the guide rail (2022) of the positioning device (202). A positioning cylinder (2023) is provided in the middle of the guide rail (2022). The two output ends of the positioning cylinder (2023) are connected to the two positioning frames (2021).

4. The junction box removal equipment for recycling waste photovoltaic modules according to claim 1, characterized in that, The visual recognition device (3) includes a support frame (302), and a number of cameras (301) are arranged on the top edge of the support frame (302). The cameras (301) are located directly above the workbench (2).

5. The junction box removal equipment for recycling waste photovoltaic modules according to claim 3, characterized in that, The positioning frame (2021) has a C-shaped side, and several auxiliary wheels are provided along the edge of the positioning frame (2021).

6. A method for removing junction boxes for recycling waste photovoltaic modules, comprising the junction box removal equipment for recycling waste photovoltaic modules according to any one of claims 1-5, characterized in that, Follow these steps: Step 1: After loading the material, perform centering, positioning, and limiting. Step 2: Visually identify the model, junction box location, and dimensions; Step 3: The junction box removal device (101) removes the junction box; Step 4: Unload the workpiece and transport it to the next process.

7. The method for removing junction boxes for recycling waste photovoltaic modules according to claim 6, characterized in that, Step 1 is as follows: the workpiece is transported from the previous process to the workbench (2), the conveyor belt (201) transports the workpiece to the working position, the positioning cylinder (2023) is started, and the positioning frame (2021) is driven to center, position and limit the workpiece on both sides.

8. The method for removing junction boxes for recycling waste photovoltaic modules according to claim 6, characterized in that, Step 2 specifically involves the camera (301) in the visual recognition device (3) recognizing the workpiece, confirming the component model of the workpiece, recognizing the position of the wire box, recognizing the size of the wire box, and transmitting the recognized information to the six-axis robot (1).

9. The method for removing junction boxes for recycling waste photovoltaic modules according to claim 6, characterized in that, Step 3 is as follows: The six-axis robot (1) moves the wire box removal device (101) above the wire box according to the information identified by the camera (301). According to the wire box size information and wire box position information given by the visual recognition device (3), the robot (1) controls the distance between the second shovel (1013) and the first shovel (1012). The six-axis robot (1) places the first shovel (1012) and the second shovel (1013) of the wire box removal device (101) against the two sides of the wire box. The first drive motor (1011) controls the second shovel (1013) to move closer to the first shovel (1012) to remove the wire box and complete the removal of the wire box.

10. The method for removing junction boxes for recycling waste photovoltaic modules according to claim 6, characterized in that, Step 4 is as follows: the six-axis robot (1) drives the wire box removal device (101) to place the removed wire box in the designated position, then the positioning cylinder (2023) is restored, the two positioning frames (2021) move away from each other to cancel the positioning and limit of the workpiece, the second drive motor (2011) is started, and the conveyor belt (201) sends the workpiece to the next process along the conveyor line.

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