Full-automatic high-beat solar panel adhesive tape pasting system

Abstract

The invention relates to the technical field of photovoltaic cell production, and discloses a full-automatic high-beat solar panel adhesive tape pasting system which comprises a transverse film covering device and a longitudinal film covering device, the transverse film covering device and the longitudinal film covering device are communicated, and each of the transverse film covering device and the longitudinal film covering device comprises a back plate rack. A deviation rectifying mechanism is arranged in the machine frame, a feeding conveying mechanism is arranged at the top of the deviation rectifying mechanism, folding channels are arranged on the two sides of the machine frame in the feeding conveying direction, and sliding rails are arranged on the two sides of the transverse film covering device in the feeding conveying direction and the two sides, not provided with the folding channels, of the longitudinal film covering device. A steel frame is connected to the sliding rails in a sliding mode. The full-automatic high-beat solar panel adhesive tape pasting system has the advantages of being safe to operate, convenient and fast to maintain and the like, the production efficiency and packaging quality of photovoltaic modules are remarkably improved, the large-scale mass production requirement is fully met, an efficient, stable and universal adhesive tape pasting solution is provided for the technical field of photovoltaic cell production, and the application prospect is wide. The method has important practical value and popularization prospect.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic cell production technology, specifically to a fully automated, high-rate-of-use solar panel tape application system. Background Technology

[0002] A single solar cell cannot be used directly as a power source. To use it as a power source, several individual cells must be connected in series and parallel and tightly packaged into a module. Solar cell modules, also called photovoltaic modules, are the core and most important part of a solar power generation system. Their function is to convert solar energy into electrical energy, which can then be stored in batteries or used to power loads. Currently, during the production process of photovoltaic modules, a coating process is required to coat the encapsulation material.

[0003] During photovoltaic module manufacturing, film strips are attached to the gaps between the cell strings to improve the yield rate during the lamination process and also to improve the module's appearance. In actual photovoltaic module processing, these film strips need to be fixed to the photovoltaic glass panel or between the cell strings.

[0004] However, existing photovoltaic module tape application methods have many technical defects. For example, a solar module flat tape application machine described in Chinese invention patent CN110143440A includes a body, a conveying mechanism mounted on the body for conveying glass, a tape application mechanism for applying tape to the glass, and a moving mechanism for driving the tape application machine to move. By having the conveying mechanism, tape application mechanism, and moving mechanism mounted on the body cooperate with each other, the machine replaces the manual operation in traditional technology, thereby achieving the goals of automating tape application, improving tape application efficiency, ensuring product quality, and reducing the workload of workers. This type of tape applicator has a low degree of automation, employing a semi-automatic operation mode. Its slow production cycle and low efficiency make it unsuitable for large-scale mass production. Furthermore, its positioning accuracy is insufficient, lacking an efficient correction mechanism and relying on manual calibration, which easily leads to tape misalignment and uneven application, directly affecting the module's encapsulation accuracy and appearance consistency. Thirdly, the tape and separator are not synchronized, and tension control is unstable, easily resulting in tape wrinkles, separator loosening, or breakage, affecting the bonding quality. Fourthly, the equipment has poor adaptability; for photovoltaic modules of different sizes and specifications, frequent manual adjustments to the mechanism parameters are required, making operation cumbersome and time-consuming, and lacking versatility. Fifthly, low tape cutting accuracy and uneven heating and bonding temperatures result in insufficient tape bonding strength, thus affecting the encapsulation reliability and lifespan of the photovoltaic modules.

[0005] Therefore, developing a solar panel tape application system that is highly automated, accurately positioned, highly adaptable, and capable of high-speed and stable operation has become a key requirement for solving the pain points of existing technologies. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a fully automatic high-cycle solar panel tape application system, which features high automation, precise positioning, synchronized loading and unloading, strong adaptability, and firm adhesion. Specifically, it solves the following technical problems: 1. The existing tape application process has a low degree of automation, relying on manual or semi-automated operation, resulting in slow production cycle and low efficiency, which cannot meet the needs of large-scale mass production. 2. Lack of efficient correction mechanism and insufficient positioning accuracy can easily lead to tape misalignment and uneven bonding, affecting the packaging accuracy and appearance consistency of components. 3. The tape and diaphragm are not synchronized in their release and take-up, and the tension control is unstable, which can easily cause tape wrinkles, diaphragm loosening or breakage, affecting the bonding quality. 4. Poor equipment adaptability; frequent manual adjustment of mechanism parameters is required for different specifications of photovoltaic modules, which is cumbersome and time-consuming. 5. Low tape cutting precision and uneven heating and bonding temperatures result in insufficient tape bonding strength, affecting the reliability and service life of photovoltaic module encapsulation.

[0007] The technical solution of the present invention to solve the above-mentioned technical problems is as follows: A fully automatic high-cycle solar panel tape application system includes a horizontal film application device and a vertical film application device, which are connected to each other. Both the horizontal and vertical film application devices include a back panel frame. A correction mechanism is provided inside the frame. A feeding and conveying mechanism is provided on the top of the correction mechanism. Folding channels are provided on both sides of the frame along the feeding and conveying direction. Slide rails are provided on both sides of the horizontal film application device along the feeding and conveying direction and on both sides of the vertical film application device without folding channels. A steel frame is slidably connected to the slide rails. A plurality of tape take-up and release mechanisms are provided on the steel frame. A plurality of diaphragm take-up and release mechanisms are provided on the side of the horizontal and vertical film application devices away from the tape take-up and release mechanisms.

[0008] The beneficial effects of this invention are: 1) This fully automated high-cycle solar panel tape application system combines a horizontal lamination device with a vertical lamination device, which are interconnected. This allows solar panels to proceed directly to the vertical lamination station after horizontal lamination without manual intervention, thus achieving continuous high-cycle production. Simultaneously, it is equipped with a motor-driven tape and separator feeding mechanism and a vacuum-adsorption feeding and conveying mechanism, realizing fully automated operation from photovoltaic module feeding, synchronous tape / separator conveying, precise lamination to automatic cutting. This completely eliminates reliance on manual or semi-automated operations, significantly improving production cycle time and operational efficiency compared to traditional equipment, fully meeting the needs of large-scale photovoltaic module production.

[0009] 2) This fully automatic high-speed solar panel tape application system, through the setting of a correction mechanism, captures the position information of the photovoltaic module in real time through a vision camera. Combined with the mutually perpendicular first slide rail, second slide rail, bidirectional slider and the lead screw drive structure of the correction motor, the position of the module can be dynamically adjusted to achieve precise correction in both X and Y directions. This effectively avoids problems such as tape offset and uneven application, and controls the tape application positioning accuracy within ±0.1mm, significantly improving the module packaging accuracy and appearance consistency.

[0010] Based on the above technical solution, the present invention can be further improved as follows.

[0011] Furthermore, the plurality of diaphragm take-up and take-down mechanisms are arranged in a rectangular array, and each of the plurality of diaphragm take-up and take-down mechanisms includes a mounting plate, on which two diaphragm wheels are rotatably connected. The diaphragm wheels on two adjacent mounting plates are staggered. Two first motors are also fixedly connected to the mounting plate. The two first motors are respectively driven and connected to the two diaphragm wheels, and the two diaphragm wheels are wound around the diaphragm.

[0012] The beneficial effects of adopting the above-mentioned further solution are that the staggered distribution of the double diaphragm wheels can achieve full coverage and protection of the tape by the diaphragm, avoiding contamination or damage to the tape during the bonding process; the independent first motor drives a single diaphragm wheel, which can precisely control the speed of diaphragm winding and unwinding, ensuring synchronization with the tape winding and unwinding action, further improving the stability of tension control, and eliminating problems such as diaphragm loosening, breakage, or tape wrinkling.

[0013] Furthermore, each of the several tape take-up and unwinding mechanisms includes a base plate, on which a second motor is fixedly connected. The output end of the motor is rotatably connected to a tape pulley on one side of the base plate. The several tape pulleys are arranged alternately, and tape is wound around each of the tape pulleys. A first cylinder located below the tape pulleys is fixedly connected to the side of the base plate. The output end of the first cylinder is driven by a second cylinder, and the output end of the second cylinder is driven by a heating head. The side of each diaphragm away from the tape pulley is sleeved on the outside of the adjacent heating head.

[0014] The advantages of adopting the above-mentioned further solutions are that the second motor independently drives the tape pulley, which can precisely adjust the tape release speed. Combined with the alternating arrangement design, it can adapt to the synchronous attachment of multiple sets of battery cells. The first and second cylinder drive structure can precisely control the bonding pressure and displacement of the heating head, ensuring that the tape is in close contact with the component surface. The heating head provides a stable bonding temperature, ensuring bonding firmness. The diaphragm sleeve heating head design can avoid the heating head directly contacting the tape, which may cause adhesion or damage, further optimizing the bonding quality.

[0015] Furthermore, a third cylinder located below the first cylinder is fixedly connected to the side of the base plate. The output end of the third cylinder is driven to connect to a swing plate that is rotatably connected to the base plate. A cutting scissor is fixedly connected to the side of the swing plate away from the base plate. One end of the tape passes through the inside of the cutting scissor and extends to below the heating head.

[0016] The beneficial effects of adopting the above-mentioned further solution are that the third cylinder drives the swing plate to move the cutting scissors, the cutting force is controllable and the speed is fast. Combined with the tape through-type design, it can achieve immediate and accurate cutting after the tape is applied, and the cut is flat and burr-free. The swing plate rotation structure makes the cutting action flexible, avoids interference with the heating head and tape application path, ensures the continuity of operation, and solves the problems of low cutting accuracy and affecting the application efficiency of traditional methods.

[0017] Furthermore, both the steel frame and the top of the opposite frame are slidably connected to sliders. Several base plates are slidably connected to the top of the slider on one side of the steel frame, and several mounting plates are slidably connected to the top of the slider on the frame side. Each of the base plates and mounting plates has a first limiting hole. Each of the two sliders has several second limiting holes that are adapted to the first limiting holes. A limiting rod extending into the adjacent second limiting hole is connected through each of the first limiting holes.

[0018] The beneficial effects of adopting the above-mentioned further solution are that the combination structure of the slider and the limiting rod enables the rapid sliding adjustment of the base plate and the mounting plate. The position can be fixed simply by inserting and removing the limiting rod, without disassembling the equipment. It can flexibly adapt to the attachment requirements of photovoltaic modules of different sizes and specifications, greatly shorten the changeover and adjustment time, improve the equipment's versatility and production flexibility, and solve the problems of poor adaptability and cumbersome operation of existing equipment.

[0019] Furthermore, the mounting plate is rotatably connected to several guide wheels on the same side as the diaphragm wheel and two encoders. Two buffer slide rails are also fixedly connected between the guide wheels. Buffer sliders are slidably connected on both buffer slide rails. One end of the diaphragm extends to the outside of the diaphragm wheel and passes between the encoder, guide wheels and buffer sliders.

[0020] The beneficial effects of adopting the above-mentioned further solutions are that the encoder monitors the diaphragm transmission tension and speed in real time, feeds back signals and dynamically adjusts the speed of the first motor to achieve precise tension control; the buffer slide rail and buffer slider can absorb tension fluctuations during the diaphragm transmission process, avoiding diaphragm loosening or excessive stretching and breakage; the guide wheel guides the diaphragm transmission path to ensure smooth transmission without deviation, further ensuring the synchronization of tape and diaphragm winding and unwinding, and improving the stability of bonding quality.

[0021] Furthermore, the correction mechanism includes a first positioning plate and a second positioning plate. The bottom of the first positioning plate is fixedly connected to a plurality of mutually perpendicular first slide rails, and the top of the second positioning plate is fixedly connected to a plurality of second slide rails adapted to the first slide rails. The plurality of second slide rails are respectively perpendicular to their adjacent first slide rails. The adjacent first slide rails and second slide rails are slidably connected to bidirectional sliders. At least two mutually perpendicular correction motors are provided on the top of the second positioning plate. The output end of the correction motor is driven and connected to two of the bidirectional sliders respectively through a lead screw. The correction mechanism also includes a vision camera, which is signal-connected to the correction motor.

[0022] The beneficial effects of adopting the above-mentioned further solution are that the vision camera captures the positional deviation of the photovoltaic module in real time, and the signal is transmitted to the correction motor. The motor drives the bidirectional slider to slide along the first and second slide rails through the lead screw, so as to achieve precise correction in both X and Y directions. The correction response is fast and the accuracy is high. It completely solves the problems of tape offset and uneven bonding caused by the lack of efficient correction mechanism and reliance on manual calibration in existing equipment, and ensures the consistency of module packaging accuracy and appearance.

[0023] Furthermore, the feeding and conveying mechanism includes a support and a conveyor belt. A back plate is placed on the top of the conveyor belt, and a plurality of battery cells arranged in a rectangular array are placed on the back plate. The top of the first positioning plate is fixedly connected to the support. Rotating rollers are rotatably connected to both sides of the support along the feeding and conveying direction. A plurality of lifting rollers are rotatably connected to the bottom of the support. The conveyor belt is sleeved on the outside of the support and the two rotating rollers, and the bottom of the conveyor belt abuts against the lifting rollers. A plurality of ventilation holes are opened on the surface of the conveyor belt, and a plurality of vacuum generators are installed inside the support.

[0024] The beneficial effects of adopting the above-mentioned further solution are that the vacuum generator adsorbs and fixes the backsheet and battery cells through the vent holes, avoiding component displacement during transportation and ensuring the accuracy of attachment and positioning; the lifting roller supports the conveyor belt, ensuring a flat transmission surface and reducing component bumps; the rotating roller drives the conveyor belt for smooth transportation, which works in conjunction with tape / separator attachment and correction actions to achieve fully automated feeding, improve production cycle and operational stability, and meet the needs of large-scale mass production.

[0025] Furthermore, the folding channel includes a storage plate and a base bracket. The storage plate is rotatably connected to the frame and the base bracket via two sets of bearings. A first nitrogen spring is provided between the storage plate and the frame, and a second nitrogen spring is provided between the storage plate and the base bracket.

[0026] The beneficial effects of adopting the above-mentioned further solutions are that the first nitrogen spring and the second nitrogen spring can flexibly adjust the support angle and force of the storage plate to adapt to the transmission needs of components of different specifications; the bearing connection reduces the rotational friction of the storage plate and ensures smooth adjustment; the folding design can be flexibly unfolded or stored according to the production scenario, saving equipment space, while providing stable support for component transmission, avoiding transmission jams, and improving the continuity of operation.

[0027] Furthermore, the top of the storage plate is provided with several automatic rollers and support slide rails in sequence along the feeding and conveying direction, and several support wheels arranged in a rectangular array are slidably connected to the support slide rails.

[0028] The beneficial effects of adopting the above-mentioned further solution are that the automatic roller and support wheel rolling transmission assembly greatly reduces the friction on the component surface and avoids scratches or damage; the support wheels are distributed in a rectangular array to ensure uniform force and stable posture during component transmission. Combined with the support structure of the folding channel, it further improves the stability of component transmission, ensures the accuracy of subsequent bonding processes, and improves product yield. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the transverse coating device of the present invention; Figure 3 This is a schematic diagram of the longitudinal coating device of the present invention; Figure 4 This is a schematic diagram of the diaphragm take-up and take-down mechanism of the present invention; Figure 5 This is a schematic diagram of the tape take-up and take-down mechanism of the present invention; Figure 6 For the present invention Figure 3 Enlarged view of point A in the middle; Figure 7 For the present invention Figure 3 Enlarged view at point B in the middle; Figure 8 This is a schematic diagram of the correction mechanism and feeding and conveying mechanism of the present invention; Figure 9 For the present invention Figure 8 Enlarged view at point C; Figure 10 This is a schematic diagram of the folded channel structure of the present invention.

[0030] In the diagram: 1. Horizontal laminating device; 2. Vertical laminating device; 3. Backplate; 4. Battery cell; 5. Frame; 6. Correction mechanism; 61. First positioning plate; 62. Second positioning plate; 63. First slide rail; 64. Second slide rail; 65. Bidirectional slider; 66. Correction motor; 67. Vision camera; 7. Feeding and conveying mechanism; 71. Support; 72. Rotating roller; 73. Lifting roller; 74. Conveyor belt; 8. Folding channel; 81. Storage plate; 82. Foot support; 83. First nitrogen spring; 84. Second nitrogen spring; 85. Automatic roller; 86. Support slide rail; 8 7. Support wheel; 9. Slide rail; 10. Steel frame; 11. Tape take-up and undo mechanism; 111. Base plate; 112. Second motor; 113. Tape pulley; 114. Tape; 115. First cylinder; 116. Second cylinder; 117. Heating head; 118. ; 1110. Cutting shears; 1112. Swing plate; 12. Diaphragm take-up and undo mechanism; 121. Mounting plate; 122. Diaphragm wheel; 123. First motor; 124. Diaphragm; 125. Guide wheel; 126. Encoder; 127. Buffer slide rail; 128. Buffer slider; 13. Slider; 14. Limit rod. Detailed Implementation

[0031] 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.

[0032] Example 1, by Figure 1-9This invention provides a fully automated, high-rate-of-use solar panel tape application system. The system includes a horizontal film application device 1 and a vertical film application device 2, which are connected to form a "vertical-horizontal" step-by-step film application path. The vertical path corresponds to 7 sets of film application mechanisms, and the horizontal path corresponds to 25 sets of film application mechanisms, which are adapted to the 6-column, 24-row battery string layout of the module, and complete the tape application of the entire panel in one go. Both the transverse laminating device 1 and the longitudinal laminating device 2 include a backplate frame 5. A correction mechanism 6 is installed inside the frame 5. The correction mechanism 6 includes a first positioning plate 61 and a second positioning plate 62. The first positioning plate 61 and the second positioning plate 62 form a stable support frame for the correction mechanism, providing an installation foundation for bidirectional correction. Several mutually perpendicular first slide rails 63 are fixedly connected to the bottom of the first positioning plate 61, and several second slide rails 64 adapted to the first slide rails 63 are fixedly connected to the top of the second positioning plate 62. Each of the second slide rails 64 is perpendicular to its adjacent first slide rail 63. Adjacent first slide rails 63 and second slide rails 64 are slidably connected to a bidirectional slider 65. The first slide rails 63 and second slide rails 64 are arranged perpendicularly to each other, providing guidance for the sliding of the bidirectional slider 65 and achieving correction strokes in the X and Y axes. At least two mutually perpendicular correction motors 66 are installed on the top of the second positioning plate 62. The correction motors 66 provide lead screw drive power and precisely adjust the displacement of the bidirectional slider 65 according to the signal from the vision camera 67. The output end of the correction motor 66 is connected to two bidirectional sliders 65 via a lead screw. Under the drive of the lead screw of the correction motor 66, the bidirectional sliders 65 drive the feeding and conveying mechanism 7 to make fine adjustments to their positions and transmit correction power.

[0033] The correction mechanism 6 also includes a vision camera 67, which is signal-connected to the correction motor 66. The vision camera 67 captures the position information of the component mark points in real time, generates position deviation data, and transmits it to the control module to provide a basis for correction. A feeding and conveying mechanism 7 is provided at the top of the correction mechanism 6. The feeding and conveying mechanism 7 includes a support 71 and a conveyor belt 74. A back plate 3 is placed on top of the conveyor belt 74, and several solar cells 4 arranged in a rectangular array are placed on the back plate 3. The top of the first positioning plate 61 is fixedly connected to the support 71. Rotating rollers 72 are rotatably connected to both sides of the support 71 along the feeding and conveying direction. Several lifting rollers 73 are rotatably connected to the bottom of the support 71. The conveyor belt 74 is sleeved on the outside of the support 71 and the two rotating rollers 72. The rotating rollers 72 drive the conveyor belt 74 to rotate, providing power for component transport. The bottom of the conveyor belt 74 abuts against the lifting rollers 73, which support the bottom of the conveyor belt 74, ensuring a flat surface and preventing component transport from being bumpy. The surface of the conveyor belt 74 has several ventilation holes, which provide airflow channels for vacuum adsorption, allowing the adsorption force to act evenly on the component surface. Several vacuum generators are installed inside the bracket 71. These vacuum generators generate adsorption force, which, through the ventilation holes on the surface of the conveyor belt 74, fixes the components and prevents shifting during transport. The frame 5 has folding channels 8 on both sides along the feeding direction. The transverse laminating device 1 has slide rails 9 on both sides along the feeding direction, and the longitudinal laminating device 2 has slide rails 9 on both sides where folding channels 8 are not provided. A steel frame 10 is slidably connected to the slide rails 9. Several tape take-up and release mechanisms 11 are installed on the steel frame 10. Each tape take-up and release mechanism 11 includes a base plate 111. A second motor 112 is fixedly connected to the base plate 111. The second motor 112 independently drives the tape pulley 113 to rotate, precisely adjusting the release speed of the tape 114; the output of the motor 112... The end is rotatably connected to a pulley 113 on one side of the base plate 111. Several pulleys 113 are arranged alternately, and each pulley 113 is wound with a tape 114. A first cylinder 115 located below the pulleys 113 is fixedly connected to the side of the base plate 111. The output end of the first cylinder 115 is driven by a second cylinder 116, and the output end of the second cylinder 116 is driven by a heating head 117. The first cylinder 115 and the second cylinder 116 work together to control the up-and-down displacement and bonding pressure of the heating head 117 to achieve precise pressing. Several diaphragms 124 are sleeved on the side away from the pulleys 113 and fitted onto the outside of the adjacent heating head 117. A third cylinder 118, located below the first cylinder 115, is fixedly connected to the side of the base plate 111. The output end of the third cylinder 118 is driven by a swing plate 1112 that is rotatably connected to the base plate 111. A cutting scissors 1110 is fixedly connected to the side of the swing plate 1112 away from the base plate 111. The swing plate 1112 transmits the driving force of the third cylinder 118, driving the cutting scissors 1110 to complete the cutting action, avoiding interference with the bonding path. One end of the tape 114 passes through the interior of the cutting scissors 1110 and extends to below the heating head 117.Furthermore, both the transverse laminating device 1 and the longitudinal laminating device 2 are provided with a plurality of diaphragm take-up and put-down mechanisms 12 on the side away from the tape take-up and put-down mechanism 11. The plurality of diaphragm take-up and put-down mechanisms 12 are arranged in a rectangular array, and each of the plurality of diaphragm take-up and put-down mechanisms 12 includes a mounting plate 121. Two diaphragm wheels 122 are rotatably connected to the mounting plate 121. The diaphragm wheels 122 on two adjacent mounting plates 121 are staggered. Two first motors 123 are also fixedly connected to the mounting plate 121. The two first motors 123 are respectively driven by the two diaphragm wheels 122, and the two diaphragm wheels 122 are wound with the diaphragm 124. The top of the steel frame 10 and the opposite frame 5 are slidably connected to sliders 13. Several base plates 111 are slidably connected to the top of the slider 13 on one side of the steel frame 10, and several mounting plates 121 are slidably connected to the top of the slider 13 on the side of the frame 5. The base plates 111 and the mounting plates 121 are all provided with first limiting holes. The top of the two sliders 13 are provided with several second limiting holes that are adapted to the first limiting holes. A limiting rod 14 is connected through the several first limiting holes, with one end extending into the adjacent second limiting hole.

[0034] Example 2, please refer to Figure 4 Based on Embodiment 1, the mounting plate 121 is rotatably connected to several guide wheels 125 on the same side as the diaphragm wheel 122 and two encoders 126. The guide wheels 125 are rotatably connected to the mounting plate 121 and on the same side as the diaphragm wheel 122, precisely guiding the transmission path of the diaphragm 124 and preventing the diaphragm 124 from shifting or tangling. The encoders 126 monitor the transmission speed and tension changes of the diaphragm 124 and the tape 114 in real time, converting the data into electrical signals and feeding them back to the first motor 123 and the second motor 112 to dynamically adjust the motor speed. Two buffer slide rails 127 are also fixedly connected between the guide wheels 125. Buffer sliders 128 are slidably connected to both buffer slide rails 127. The buffer slide rails 127 and buffer sliders 128 constitute a tension buffer mechanism. When the diaphragm 124 or tape 114 experiences instantaneous tension fluctuations, the buffer sliders 128 slide along the buffer slide rails 127 to release or collect part of the diaphragm or tape, absorbing the tension peak. One end of the diaphragm 124 extends to the outside of the diaphragm wheel 122 and passes between the encoder 126, the guide wheel 125 and the buffer slider 128.

[0035] Example 3, please refer to Figure 10Based on Embodiment 1, the folding channel 8 includes a storage plate 81 and a support bracket 82. The storage plate 81 is rotatably connected to the frame 5 and the support bracket 82 via two sets of bearings 80. A first nitrogen spring 83 is provided between the storage plate 81 and the frame 5. A safety pin is provided at the connection between the storage plate 81 and the frame 5, and a second nitrogen spring 84 is provided between the storage plate 81 and the support bracket 82. Safety protection hard limit mechanisms are provided at the connection between the storage plate 81 and the frame 5, and at the connection between the storage plate 81 and the support bracket 82. Several automatic rollers 85 and support slide rails 86 are sequentially arranged on the top of the storage plate 81 along the feeding direction. Several support wheels 87 arranged in a rectangular array are slidably connected to the support slide rails 86. When it is necessary to replace the material reel or repair the equipment, the operator pulls out the safety pin of the folding channel 8 to release the locking state of the storage plate 81. Manually push the storage plate 81 to rotate the bearing 80, thus unfolding the folding channel 8. The first nitrogen spring 83 and the second nitrogen spring 84 provide support, ensuring that the storage plate 81 maintains a stable unfolding angle, forming a passage for operators to enter the production line. Before operators enter, the safety protection hard limit mechanism automatically locks to prevent the storage plate 81 from accidentally resetting. After the operation is completed, push the storage plate 81 in the opposite direction to reset it, insert the safety pin to lock it, and the folding channel 8 resumes its transmission function, ensuring operational safety and equipment continuity.

[0036] Working principle: This invention is based on the core logic of "modular collaboration + precise control + full-process automation", and achieves high-speed and high-precision tape application through the orderly linkage of various functional mechanisms. First, the component backplate 3 is conveyed to the designated station via the belt conveyor 7. The vacuum chamber inside the frame 5 adsorbs and fixes it to prevent displacement. The vision camera 67 uses a CCD camera to capture the position deviation of the component mark point and feeds it back to the UVW alignment platform and the correction mechanism 6 to complete the precise X and Y bidirectional correction. Then, the 7 sets of longitudinal laminating devices 2 and the 25 sets of transverse laminating devices 1 start synchronously. The first motor 123 and the second motor 112 drive the tape winding and unwinding mechanism 11 and the diaphragm winding and unwinding mechanism 12 to wind and unwind. With the help of the encoder 126 and the buffer area composed of the buffer slide rail 127 and the buffer slider 128, the tension is stably controlled. The tape 114 is pulled by the clamp pull-out mechanism and hot-pressed and ironed by the heating head 117. The cutter 1110 completes the instant and precise cutting. No manual intervention is required throughout the process. The safety design of the folding channel 8 ensures convenient maintenance. Finally, the entire process of laminating is completed within 28 seconds, which is compatible with 182-210mm specification components.

[0037] Implementation steps for the first innovation point: Step 1: After the equipment is started, the belt conveyor system of the feeding and conveying mechanism 7 runs automatically. The guide plate performs coarse positioning on the component back plate 3 and conveys it to the vacuum adsorption station. The vacuum fan inside the frame 5 starts and adsorbs and fixes the component through the air vents on the surface of the conveyor belt 74 to prevent slippage during transmission. Step 2: The first set of CCD vision cameras captures the component mark points, completes the position deviation calculation within 1 second and transmits it to the UVW alignment platform. The platform completes X and Y bidirectional correction within 2 seconds to ensure that the positioning accuracy meets the standard. Step 3: The laminating mechanism of the longitudinal laminating device 2 is started synchronously. The second motor 112 of the 7-set tape take-up and release mechanism 11 drives the tape wheel 113 to release the tape 114. The first motor 123 of the diaphragm take-up and release mechanism 12 synchronously drives the diaphragm wheel 122 to release the diaphragm 124. The encoder 126 monitors the transmission speed in real time. The buffer area composed of the buffer slide rail 127 and the buffer slider 128 absorbs tension fluctuations to ensure that the two are transported synchronously. The first cylinder 115 and the second cylinder 116 drive the heating head 117 to move downward. The hot pressing and ironing tape 114 is bonded for 3 seconds. Then the third cylinder 118 drives the swing plate 1112 to drive the cutting scissors 1110 to complete the instant cutting. Step 4: After the longitudinal lamination is completed, the components are transferred to the workstation of the transverse lamination device 1 via conveyor belt 74. The visual positioning and correction steps are repeated for 3 seconds. 25 transverse lamination mechanisms simultaneously perform tape 114 release, hot pressing and cutting operations. Step 5: After the horizontal film coating is completed, the vacuum adsorption is released, and the components are conveyed to the equipment outlet end by the automatic roller 85 and support wheel 87 of the folding channel 8. There is no manual intervention throughout the process, and the total cycle time is controlled within 28 seconds.

[0038] Implementation steps for the second innovation point: Step 1: After the component arrives at the positioning station, the CCD vision camera 67 is activated to capture images of the preset mark points on the component surface and generate position deviation data. Step 2: The deviation data is transmitted to the control module of the UVW alignment platform in real time. The control module drives the two mutually perpendicular correction motors 66 of the correction mechanism 6, which in turn drive the bidirectional slider 65 to slide along the first slide rail 63 and the second slide rail 64 via the lead screw. Step 3: The bidirectional slider 65 is linked with the first positioning plate 61, which drives the components on the feeding and conveying mechanism 7 to make bidirectional fine adjustments in X and Y. During the adjustment process, the vision camera 67 provides real-time feedback of position information to form a closed-loop control until the component deviation is ≤0.3mm. The correction motor 66 then stops operating, and the precise positioning is completed.

[0039] The third innovation point implementation steps: Step 1: Equipment pre-processing stage, adjust the angle of the guide wheel 125 of the diaphragm take-up and release mechanism 12 and the initial position of the buffer slider 128 to ensure smooth transmission path of the diaphragm 124; preset the tension threshold through the encoder 126 to form a linkage control with the first motor 123 and the second motor 112; Step 2: During the lamination operation, while the second motor 112 drives the belt pulley 113 to release the belt 114, the first motor 123 synchronously drives the diaphragm pulley 122 to release the diaphragm 124, and the conveying speed of the belt 114 and the diaphragm 124 is consistent. Step 3: Encoder 126 monitors the tension changes of diaphragm 124 and tape 114 in real time. When the tension exceeds the threshold, it sends a feedback signal to the first motor 123 and the second motor 112. The motors adjust their speed to reduce the tension. When the tension is insufficient, the buffer slider 128 slides along the buffer slide rail 127 to release the buffered diaphragm 124. The tape 114 replenishes the tension to ensure that both remain flat and taut at all times, avoiding wrinkles or breakage.

[0040] The fourth innovation point implementation steps: Step 1: Based on the battery cell size 182 / 210mm and the 6-column 24-row layout requirements of the component to be processed, pull out the limiting rod 14 on the slider 13 to release the fixation between the base plate 111 of the tape take-up mechanism 11 and the mounting plate 121 of the diaphragm take-up mechanism 12. Step 2: Slide the bottom plate 111 and the mounting plate 121 along the top of the slider 13, and adjust the spacing of the 7 longitudinal groups and 25 transverse groups of the film covering mechanism so that the release position of the tape 114 corresponds precisely to the gap of the battery string. The spacing adjustment range is adapted to the spacing requirements of the 182-210mm battery cell 4. Step 3: After adjustment, insert the limiting rod 14 into the first limiting hole and the corresponding second limiting hole to fix the position of the base plate 111 and the mounting plate 121. No equipment disassembly is required, and the changeover adjustment time is ≤5 minutes.

[0041] Application Notes: Using the system of this invention, the film application cycle can reach 28 seconds / piece with a yield rate of 99.5%; while using traditional semi-automatic equipment, the cycle is 40 seconds / piece with a yield rate of 98%.

[0042] In summary, the fully automatic high-cycle solar panel tape application system disclosed in this invention integrates core functional modules such as a correction mechanism 6, a feeding and conveying mechanism 7, a tape take-up and release mechanism 11, a diaphragm take-up and release mechanism 12, and a folding channel 8 through the coordinated layout of the transverse laminating device 1 and the longitudinal laminating device 2. This constructs a fully automated closed-loop operation of "feeding-positioning-laminating-cutting-output". The system innovatively adopts a bidirectional correction design that links the vision camera 67 with the UVW alignment platform, a tension control scheme that coordinates the motor-encoder-buffer mechanism, a quick-adaptation structure combining the slider 13 and the limit rod 14, and a folding channel 8 with safety protection. This completely solves the core pain points of existing technologies, such as low automation, insufficient positioning accuracy, asynchronous take-up and release, poor adaptability, and insufficient bonding firmness. It not only achieves high-speed full-area film coating within 28 seconds, ensuring precise bonding accuracy of ±0.1-0.3mm, but also is compatible with photovoltaic modules of 182-210mm specifications. It also has advantages such as safe operation and convenient maintenance, significantly improving the production efficiency and encapsulation quality of photovoltaic modules, fully meeting the needs of large-scale mass production, and providing an efficient, stable, and universal tape application solution for the field of photovoltaic cell production technology. It has important practical value and promising prospects for promotion.

[0043] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0044] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A fully automatic high-rate solar panel tape application system, comprising a transverse laminating device (1) and a longitudinal laminating device (2), wherein the transverse laminating device (1) and the longitudinal laminating device (2) are connected, characterized in that: Both the transverse laminating device (1) and the longitudinal laminating device (2) include a back plate frame (5). The frame (5) is equipped with a correction mechanism (6). The top of the correction mechanism (6) is equipped with a feeding and conveying mechanism (7). The frame (5) is equipped with folding channels (8) on both sides along the feeding and conveying direction. The transverse laminating device (1) and the longitudinal laminating device (2) are equipped with slide rails (9) on both sides along the feeding and conveying direction and on both sides without folding channels (8). A steel frame (10) is slidably connected to the slide rails (9). Several tape take-up and release mechanisms (11) are provided on the steel frame (10). Several diaphragm take-up and release mechanisms (12) are provided on the side of the transverse laminating device (1) and the longitudinal laminating device (2) away from the tape take-up and release mechanism (11).

2. The automatic high-rate solar panel tape application system according to claim 1, characterized in that: The plurality of diaphragm take-up and take-down mechanisms (12) are arranged in a rectangular array, and each of the plurality of diaphragm take-up and take-down mechanisms (12) includes a mounting plate (121). Two diaphragm wheels (122) are rotatably connected to the mounting plate (121). The diaphragm wheels (122) on two adjacent mounting plates (121) are staggered. Two first motors (123) are also fixedly connected to the mounting plate (121). The two first motors (123) are respectively driven and connected to the two diaphragm wheels (122). The two diaphragm wheels (122) are both wrapped around the diaphragm (124).

3. The automatic high-rate solar panel tape application system according to claim 2, characterized in that: Each of the tape take-up and take-down mechanisms (11) includes a base plate (111). A second motor (112) is fixedly connected to the base plate (111). The output end of the motor (112) is connected to a tape pulley (113) rotatably connected to one side of the base plate (111). The tape pulleys (113) are arranged alternately, and tape (114) is wound around each tape pulley (113). A first cylinder (115) located below the tape pulley (113) is fixedly connected to the side of the base plate (111). A second cylinder (116) is driven to the output end of the first cylinder (115). A heating head (117) is driven to the output end of the second cylinder (116). The side of each diaphragm (124) away from the tape pulley (113) is sleeved on the outside of the adjacent heating head (117).

4. The fully automatic high-cycle solar panel tape application system according to claim 3, characterized in that: A third cylinder (118) located below the first cylinder (115) is fixedly connected to the side of the base plate (111). The output end of the third cylinder (118) is driven to connect to a swing plate (1112) that is rotatably connected to the base plate (111). A cutter (1110) is fixedly connected to the side of the swing plate (1112) away from the base plate (111). One end of the tape (114) passes through the inside of the cutter (1110) and extends to the bottom of the heating head (117).

5. The fully automatic high-cycle solar panel tape application system according to claim 3, characterized in that: The top of the steel frame (10) and the frame (5) opposite it are slidably connected to sliders (13). The top of the slider (13) on one side of the steel frame (10) is slidably connected to several base plates (111), and the top of the slider (13) on the side of the frame (5) is slidably connected to several mounting plates (121). The base plates (111) and the mounting plates (121) are all provided with first limiting holes. The tops of the two sliders (13) are all provided with several second limiting holes that are adapted to the first limiting holes. A limiting rod (14) extending to the adjacent second limiting hole is connected through the first limiting hole.

6. The fully automatic high-cycle solar panel tape application system according to claim 2, characterized in that: The mounting plate (121) is rotatably connected to several guide wheels (125) on the same side as the diaphragm wheel (122) and two encoders (126). Two buffer slide rails (127) are also fixedly connected between the guide wheels (125). Buffer sliders (128) are slidably connected on both buffer slide rails (127). One end of the diaphragm (124) extends to the outside of the diaphragm wheel (122) and passes between the encoder (126), guide wheels (125) and buffer sliders (128).

7. The fully automatic high-cycle solar panel tape application system according to claim 1, characterized in that: The correction mechanism (6) includes a first positioning plate (61) and a second positioning plate (62). The bottom of the first positioning plate (61) is fixedly connected with a plurality of mutually perpendicular first slide rails (63). The top of the second positioning plate (62) is fixedly connected with a plurality of second slide rails (64) adapted to the first slide rails (63). The plurality of second slide rails (64) are perpendicular to their adjacent first slide rails (63). The adjacent first slide rails (63) and second slide rails (64) are slidably connected to bidirectional sliders (65). At least two mutually perpendicular correction motors (66) are provided on the top of the second positioning plate (62). The output end of the correction motors (66) is driven and connected to two of the bidirectional sliders (65) respectively through a lead screw. The correction mechanism (6) also includes a vision camera (67), which is signal-connected to the correction motor (66).

8. The fully automatic high-cycle solar panel tape application system according to claim 7, characterized in that: The feeding and conveying mechanism (7) includes a bracket (71) and a conveyor belt (74). A back plate (3) is placed on the top of the conveyor belt (74). A number of battery cells (4) arranged in a rectangular array are placed on the back plate (3). The top of the first positioning plate (61) is fixedly connected to the bracket (71). Rotating rollers (72) are rotatably connected to both sides of the bracket (71) along the feeding and conveying direction. A number of lifting rollers (73) are rotatably connected to the bottom of the bracket (71). The conveyor belt (74) is sleeved on the outside of the bracket (71) and the two rotating rollers (72), and the bottom of the conveyor belt (74) abuts against the lifting rollers (73). A number of ventilation holes are opened on the surface of the conveyor belt (74). A number of vacuum generators are installed inside the bracket (71).

9. The fully automatic high-cycle solar panel tape application system according to claim 1, characterized in that: The folding channel (8) includes a storage plate (81) and a base bracket (82). The storage plate (81) is rotatably connected to the frame (5) and the base bracket (82) through two sets of bearings (80). A first nitrogen spring (83) is provided between the storage plate (81) and the frame (5), and a second nitrogen spring (84) is provided between the storage plate (81) and the base bracket (82).

10. The fully automatic high-cycle solar panel tape application system according to claim 9, characterized in that: The top of the receiving plate (81) is provided with a number of automatic rollers (85) and support slide rails (86) in sequence along the feeding and conveying direction. A number of support wheels (87) arranged in a rectangular array are slidably connected on the support slide rails (86).

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