Intelligent disassembling and cutting system and method for retired photovoltaic module

Abstract

The invention provides an intelligent dismantling and cutting system and method for a retired photovoltaic module, and the system comprises a feeding device, a recognition device, a dismantling device, a cutting device, a caching device and a controller, and the recognition device is used for recognizing the identification information and structural features of the photovoltaic module; the dismantling device comprises a frame dismantling device, a junction box dismantling device and a lead dismantling device, and the conveying unit conveys the photovoltaic module to at least one of the frame dismantling device, the junction box dismantling device and the lead dismantling device according to the identification information and structural characteristics of the photovoltaic module identified by the identification device; and the caching device is used for temporarily storing the cut photovoltaic module. According to the invention, automation and intellectualization of disassembling and cutting links are realized, unified processing of photovoltaic modules of multiple models and multiple structures is realized through identification of the photovoltaic modules and generation of disassembling and cutting strategies, the flexibility and adaptability of the system are improved, the disassembling efficiency is improved, the requirements of manual pre-sorting and tool adjustment are reduced, and the safety risk is reduced.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic module recycling technology, and in particular to an intelligent dismantling and cutting system and method for retired photovoltaic modules. Background Technology

[0002] Photovoltaic modules typically consist of tempered glass, crystalline silicon cells, EVA film, backsheet, aluminum frame, junction box, and leads. With the continuous expansion of global photovoltaic installations, many early-built photovoltaic power plants are entering their decommissioning phase. These decommissioned modules are rich in high-value resources such as glass, silicon wafers, silver grid lines, copper strips, and aluminum, but also contain organic matter such as EVA film, backsheet resin, and fluorinated polymers, as well as some harmful components. Simple landfilling or crude crushing not only wastes resources but also poses environmental and safety risks such as heavy metal migration and the release of organic pollutants. Therefore, the industry has gradually formed a resource-based recycling process: "front-end dismantling → thermal debinding → physical / wet sorting and purification." Front-end dismantling involves removing the aluminum frame, junction box, and external leads, and, if necessary, cutting or slicing the modules to fit the furnace size and feeding method of the downstream pyrolysis unit.

[0003] Currently, there are three main types of front-end disassembly methods in engineering practice: the first is manual disassembly, which relies entirely on manual labor. This involves operators using simple tools such as pry bars, hammers, and handheld cutters to pry off aluminum frames, remove junction boxes and cables, and cut them. This method has low equipment investment, but high labor intensity, low efficiency, and high safety risks. The disassembly quality and the integrity rate of glass and battery cells are highly dependent on the workers' experience, which is not suitable for the need for continuous processing of large-scale retired modules. Second, dismantling equipment is mostly used as standalone units or simply connected in series. The frame removal tools, junction box cutting devices, and conveying equipment are designed independently, lacking a unified system architecture and central control. This leads to mismatches in cycle time between processes, accumulation of work-in-process, and repeated handling of materials. Third, most equipment is designed for specific models and structures, and has poor adaptability to retired components of different sizes, versions, and structures such as single-glass, double-glass, and fluorinated backsheets. This requires manual pre-sorting and frequent tooling adjustments, resulting in insufficient automation and flexibility. Fourth, there is poor connection with the downstream pyrolysis unit. The dismantling and discharge postures at the front end are inconsistent, and the cycle time is unstable. Extra manual sorting, flipping, and stacking are often required to meet the feeding requirements of the pyrolysis unit. Fifth, there is a lack of intelligent control and safety interlocking mechanisms based on image and sensor data. The monitoring of key parameters such as clamping force, displacement, and load changes during dismantling is insufficient, which can easily lead to problems such as glass edge cracking and large-area breakage of battery cells. Summary of the Invention

[0004] The purpose of this invention is to at least partially solve one of the technical problems in related technologies. To this end, embodiments of this invention provide an intelligent dismantling and cutting system and method for retired photovoltaic modules, enabling unified processing of photovoltaic modules of various models and structural types, improving dismantling efficiency, and reducing manual intervention and safety risks.

[0005] One embodiment of the present invention proposes an intelligent dismantling and cutting system for retired photovoltaic modules, comprising: a feeding device, an identification device, a dismantling device, a cutting device, a buffer device, and a controller. The feeding port of the identification device is connected to the discharging port of the feeding device, and the identification device is used to identify the identification information and structural features of the photovoltaic module. The dismantling device is located downstream of the identification device, and the dismantling device includes a frame dismantling device, a junction box dismantling device, and a lead wire dismantling device. According to the identification information and structural features of the photovoltaic module identified by the identification device, the conveying unit conveys the photovoltaic module to at least one of the frame dismantling device, the junction box dismantling device, and the lead wire dismantling device. The cutting device is located downstream of the dismantling device. The feeding port of the buffer device is connected to the discharging port of the dismantling device, and the buffer device is used to temporarily store the cut photovoltaic module. The controller is electrically connected to the identification device, the dismantling device, the conveying unit, and the cutting device.

[0006] In some embodiments, the conveying unit includes a clamping device for conveying the photovoltaic module between the identification device, the removal device, the cutting device, and the buffer device.

[0007] In some embodiments, the identification device is provided with a positioning clamp for positioning the photovoltaic module.

[0008] Another embodiment of the present invention proposes an intelligent dismantling and cutting method for decommissioned photovoltaic modules, which utilizes the aforementioned intelligent dismantling and cutting system for decommissioned photovoltaic modules and includes the following steps: S1. The photovoltaic modules are fed to the identification device through the feeding device. The identification information and structural features of the photovoltaic modules are identified, a dismantling and cutting strategy is generated, and the information of the dismantling and cutting strategy is sent to the controller. The controller controls the conveying unit to transport the photovoltaic modules to different dismantling devices for dismantling operations. S2. After dismantling, when the photovoltaic modules need to be cut, the controller controls the conveying unit to transport the dismantled photovoltaic modules to the cutting device for cutting to meet the size requirements for entering the furnace. The cut photovoltaic modules are stored in the buffer device for temporary storage.

[0009] In some embodiments, in step S1, the identification information includes at least one of nameplate, model, barcode, and QR code, and the structural features include at least one of size, structure type, junction box location, and obviously damaged area.

[0010] In some embodiments, in step S1, the identification device further includes an image acquisition device, which is used to capture images of the photovoltaic module, and the identification device sends the image information to the controller.

[0011] In some embodiments, in step S1, the disassembly and cutting strategy includes whether to remove the frame, whether to remove the junction box, whether to remove the lead wire, whether to cut, the execution order of disassembly, the operating parameters of disassembly and cutting, and the cutting path.

[0012] In some embodiments, in step S1, the cutting path is determined based on the furnace size of the pyrolysis device, the component damage distribution, and the preset cutting rules.

[0013] In some embodiments, in step S1, the photovoltaic module is transported to different removal devices by a clamping device.

[0014] In some embodiments, in step S2, the cut photovoltaic modules are adjusted in posture by the conveying unit and placed in the buffer device for stacking and storage. Attached Figure Description

[0015] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the following description of the embodiments taken in conjunction with the accompanying drawings. in: Figure 1 This is a schematic diagram of the intelligent disassembly and cutting system for decommissioned photovoltaic modules according to an embodiment of the present invention; Figure label: 1. Feeding device; 2. Identification device; 3. Removal device; 4. Cutting device; 5. Buffer device. Detailed Implementation

[0016] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0017] The intelligent dismantling and cutting system and method for decommissioned photovoltaic modules according to embodiments of the present invention are described below with reference to the accompanying drawings.

[0018] like Figure 1As shown, one embodiment of the present invention proposes an intelligent dismantling and cutting system for retired photovoltaic modules, comprising: a feeding device 1, an identification device 2, a dismantling device 3, a cutting device 4, a buffer device 5, and a controller. The feeding port of the identification device 2 is connected to the discharging port of the feeding device 1, and the identification device 2 is used to identify the identification information and structural features of the photovoltaic module. The dismantling device 3 is located downstream of the identification device 2, and the dismantling device 3 includes a frame dismantling device, a junction box dismantling device, and a lead wire dismantling device. According to the identification information and structural features of the photovoltaic module identified by the identification device 2, the conveying unit conveys the photovoltaic module to at least one of the frame dismantling device, the junction box dismantling device, and the lead wire dismantling device. The cutting device 4 is located downstream of the dismantling device 3. The feeding port of the buffer device 5 is connected to the discharging port of the dismantling device 3, and the buffer device 5 is used to temporarily store the cut photovoltaic module. The controller is electrically connected to the identification device 2, the dismantling device 3, the conveying unit, and the cutting device 4 respectively.

[0019] Furthermore, the identification device 2 includes an image acquisition device and an encoding identification device.

[0020] This invention, through the inclusion of an identification device 2 and a controller, automates and intelligently processes the disassembly and cutting process. By identifying the photovoltaic modules, it generates disassembly and cutting strategies, enabling unified processing of photovoltaic modules of various models and structures. This improves system flexibility and adaptability, increases disassembly efficiency, reduces the need for manual pre-sorting and tooling adjustments, and lowers safety risks. It can handle photovoltaic modules with diverse structural characteristics without requiring multiple production lines, thus enhancing processing capacity and economic efficiency while reducing costs.

[0021] In some embodiments, the conveying unit includes a clamping device for conveying the photovoltaic module between the identification device 2, the removal device 3, the cutting device 4, and the buffer device 5.

[0022] In some embodiments, the identification device 2 is equipped with a positioning clamp for positioning the photovoltaic module. The controller sends instructions to the positioning clamp regarding the clamping position and transport path, causing the positioning clamp to automatically adjust the clamping position, clamping method, and clamping force to flexibly clamp the photovoltaic module and transport it to the designated position.

[0023] By monitoring and dynamically adjusting parameters such as clamping force online, the safety of the disassembly process and the integrity rate of glass and battery cells are improved, providing better raw material conditions for subsequent pyrolysis and wet purification.

[0024] like Figure 1 As shown, another embodiment of the present invention proposes an intelligent dismantling and cutting method for decommissioned photovoltaic modules, which utilizes the aforementioned intelligent dismantling and cutting system for decommissioned photovoltaic modules and includes the following steps: S1. The photovoltaic module is fed to the identification device 2 through the feeding device 1. The identification information and structural features of the photovoltaic module are identified, a dismantling and cutting strategy is generated, and the information of the dismantling and cutting strategy is sent to the controller. The controller controls the conveying unit to transport the photovoltaic module to different dismantling devices 3 for dismantling operations. S2, after dismantling, when the photovoltaic modules need to be cut, the controller controls the conveying unit to transport the dismantled photovoltaic modules to the cutting device 4 for cutting to meet the size requirements for entering the furnace. The cut photovoltaic modules are temporarily stored in the buffer device 5 for later use.

[0025] The method described in this invention automates and intelligently processes the disassembly and cutting steps. By identifying photovoltaic modules, it generates disassembly and cutting strategies, enabling unified processing of photovoltaic modules of various models and structures. This improves system flexibility and adaptability, increases disassembly efficiency, reduces the need for manual pre-sorting and tooling adjustments, and lowers safety risks. It can handle photovoltaic modules with diverse structural features without requiring multiple production lines, thus enhancing processing capacity and economic efficiency while reducing costs.

[0026] Furthermore, the dismantling device 3 includes a frame dismantling device, a junction box dismantling device, and a lead wire dismantling device. In the frame dismantling device, the system initiates the frame dismantling process according to the dismantling strategy. The controlled execution unit performs a gradual peeling along the edge of the photovoltaic module, monitors the load changes during the peeling process, and dynamically adjusts the peeling speed and force based on feedback signals. In the junction box dismantling device and the lead wire dismantling device, the system locates and clamps the junction box area according to the identification position and structural characteristics of the junction box, controls the cutting execution unit to cut or remove the fixed part of the junction box along a predetermined path, and controls the lead wire dismantling device to remove the lead wire at the appropriate position.

[0027] Furthermore, the controller controls the cutting device 4 to perform straight or multi-segment cutting operations on the photovoltaic module along the guide path, dividing the photovoltaic module into whole plates or pieces that meet the requirements for entering the furnace. At the same time, during the cutting process, vibration and stress concentration are reduced by reasonable support and operating parameter control. The disassembled photovoltaic module is then sent into the buffer device 5 by the conveying device.

[0028] In some embodiments, in step S1, the identification information includes at least one of nameplate, model, barcode, and QR code, and the structural features include at least one of size, structure type, junction box location, and obviously damaged area.

[0029] In some embodiments, in step S1, the identification device 2 further includes an image acquisition device, which is used to capture images of the photovoltaic module, and the identification device 2 sends the image information to the controller.

[0030] In some embodiments, in step S1, the disassembly and cutting strategy includes whether to remove the frame, whether to remove the junction box, whether to remove the lead wire, whether to cut, the execution order of disassembly, the running parameters of disassembly and cutting, and the cutting path.

[0031] In some embodiments, in step S1, the cutting path is determined based on the furnace size of the pyrolysis device, the component damage distribution, and the preset cutting rules.

[0032] In some embodiments, in step S1, the photovoltaic module is conveyed to different removal devices 3 by a clamping device.

[0033] In some embodiments, in step S2, the cut photovoltaic modules are adjusted in posture by the conveying unit and placed in the buffer device 5 for stacking and storage.

[0034] Furthermore, the discharge speed of the buffer device 5 is matched with the feeding speed of the pyrolysis line. This enables a stable connection between the front-end disassembly and cutting system and the back-end pyrolysis system, reducing work-in-process accumulation and manual handling, and improving the processing capacity and operating efficiency of the entire process chain for the resource utilization of retired photovoltaic modules.

[0035] Furthermore, the buffer device 5 adjusts the posture and stacks the photovoltaic modules according to the feeding method of the pyrolysis device, and controls the discharge speed according to the feeding rhythm of the pyrolysis line, so as to send the photovoltaic modules into the feeding port of the pyrolysis device in a rhythmic manner, thereby forming a complete front-end intelligent disassembly process from the entry of photovoltaic modules into the factory to their entry into the pyrolysis device.

[0036] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0037] Furthermore, the terms "first" and "second" are used 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 as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0038] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," 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, an electrical connection, or a connection that allows communication between them; 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 limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0039] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of 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. "Below," "below," and "under" 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.

[0040] In this invention, the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0041] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A smart dismantling and cutting system for retired photovoltaic modules, characterized in that, include: Feeding device; An identification device, wherein the inlet of the identification device is connected to the outlet of the feeding device, and the identification device is used to identify the identification information and structural features of the photovoltaic module; A removal device is located downstream of the identification device. The removal device includes a frame removal device, a junction box removal device, and a lead wire removal device. Based on the identification information and structural features of the photovoltaic module identified by the identification device, the conveying unit conveys the photovoltaic module to at least one of the frame removal device, the junction box removal device, and the lead wire removal device. A cutting device, wherein the cutting device is located downstream of the dismantling device; A buffer device, the inlet of which is connected to the outlet of the dismantling device, is used to temporarily store the cut photovoltaic modules; The controller is electrically connected to the identification device, the dismantling device, the conveying unit, and the cutting device.

2. The intelligent dismantling and cutting system for decommissioned photovoltaic modules according to claim 1, characterized in that, The conveying unit includes a clamping device for conveying photovoltaic modules between the identification device, the removal device, the cutting device, and the buffer device.

3. The intelligent dismantling and cutting system for decommissioned photovoltaic modules according to claim 1, characterized in that, The identification device is equipped with a positioning clamp, which is used to position the photovoltaic module.

4. A method for intelligent dismantling and cutting retired photovoltaic modules, characterized in that, The intelligent dismantling and cutting system for decommissioned photovoltaic modules according to any one of claims 1-3 includes the following steps: S1. The photovoltaic module is fed to the identification device through the feeding device. The identification information and structural features of the photovoltaic module are identified, a dismantling and cutting strategy is generated, and the information of the dismantling and cutting strategy is sent to the controller. The controller controls the conveying unit to transport the photovoltaic module to different dismantling devices for dismantling operations. S2, after dismantling, when the photovoltaic modules need to be cut, the controller controls the conveying unit to transport the dismantled photovoltaic modules to the cutting device for cutting to meet the size requirements for entering the furnace. The cut photovoltaic modules are stored in the buffer device for temporary storage.

5. The intelligent dismantling and cutting method for decommissioned photovoltaic modules according to claim 4, characterized in that, In step S1, the identification information includes at least one of the following: nameplate, model, barcode, and QR code, and the structural features include at least one of the following: size, structural type, junction box location, and obviously damaged area.

6. The intelligent dismantling and cutting method for decommissioned photovoltaic modules according to claim 4, characterized in that, In step S1, the identification device further includes an image acquisition device, which is used to capture images of the photovoltaic module, and the identification device sends the image information to the controller.

7. The intelligent dismantling and cutting method for decommissioned photovoltaic modules according to claim 4, characterized in that, In step S1, the disassembly and cutting strategy includes whether to remove the frame, whether to remove the junction box, whether to remove the lead wire, whether to cut, the execution order of disassembly, the running parameters of disassembly and cutting, and the cutting path.

8. The intelligent dismantling and cutting method for decommissioned photovoltaic modules according to claim 7, characterized in that, In step S1, the cutting path is determined based on the furnace size of the pyrolysis device, the distribution of component damage, and the preset cutting rules.

9. The intelligent dismantling and cutting method for decommissioned photovoltaic modules according to claim 4, characterized in that, In step S1, the photovoltaic modules are transported to different removal devices using a clamping device.

10. The intelligent dismantling and cutting method for decommissioned photovoltaic modules according to claim 4, characterized in that, In step S2, the cut photovoltaic modules are adjusted in posture by the conveying unit and then stacked and stored in the buffer device.

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