Full-automatic production line and production process for photovoltaic module frame

Abstract

The application relates to the technical field of mechanical equipment, and discloses a full-automatic production line and production process for a photovoltaic module frame, which comprises at least one set of first frame production line and at least one set of second frame production line; the first frame production line comprises, sequentially arranged along a conveying direction, a first steel belt feeding station, a first steel belt butt joint station, a first storage buffer station, a first flattening station, a first front punching station, a first forming station, a first rear punching station and a first cutting station; the first cutting station comprises at least one guide channel and at least two cutting knives oppositely arranged in an inclined mode; the cutting knives are arranged in a skew mode with the extension direction of the guide channel, so that the fixed-length cutting of continuous strip-shaped materials and the end inclined angle forming can be synchronously performed on line; the first cutting station capable of simultaneously cutting and cutting an inclined angle is arranged downstream of the first rear punching station, so that the cutting and the cutting of an inclined angle can be realized on line, and the production efficiency is high.

Description

Technical Field

[0001] This invention relates to the field of mechanical equipment technology, and more specifically, to a fully automated production line and manufacturing process for photovoltaic module frames. Background Technology

[0002] Currently, the production of photovoltaic module frames mainly adopts a multi-process, single-machine operation mode. A typical process includes: uncoiling the steel strip, positioning and punching, bending, and cutting. The cut photovoltaic module frames are then collected and transported to a corner-cutting mechanism for offline beveling. This design has the following disadvantages: First, it requires a separate corner-cutting device, increasing equipment costs and lengthening the production line, requiring more space. Second, the beveling process requires secondary positioning, which may lead to misalignment and inaccurate beveling. Furthermore, the photovoltaic module frames may suffer scratches, twisting, and other defects during handling and secondary positioning. Third, the offline beveling method easily leads to increased waste, mainly for the following reasons: Firstly, during secondary positioning, the cutting process requires clamping space and machining allowance. In the offline corner-cutting process, the corner-cutting machine's clamps must hold the end of the profile before sawing. To ensure that the corner saw blade does not cut the clamp and that the clamp can hold it firmly, the length of the photovoltaic module frame must be longer than the final product length when cutting to length. However, this section of material that should be good quality is cut off as waste material during the corner sawing process. Secondly, the secondary positioning may cause the corner to shift, which leads to an increase in the defect rate of the product, resulting in some photovoltaic module frames being scrapped and becoming waste products.

[0003] Patent CN116275276A discloses a high-efficiency cutting process for solar aluminum frames. Through material laying, grouping, feeding, and sawing, it achieves the simultaneous sawing of bundled long profiles into short profiles with symmetrical 45° bevel angles at both ends using a double-head sawing machine. The implicit process involves: extruding steel strips, cutting them into long profiles, and sawing the long profiles to form 45° bevel angles. This shows that the existing process still requires first cutting the formed continuous photovoltaic frame into long profiles, and then performing offline beveling and cutting. This still requires secondary positioning, which may lead to misalignment and inaccurate bevel angles. Furthermore, cutting the formed continuous photovoltaic frame into long profiles first implies the need for a separate beveling device.

[0004] Therefore, there is an urgent need to develop a fully automated continuous production line for photovoltaic module frames to solve the problem of low production efficiency in the existing technology of first cutting the photovoltaic module frame and then cutting the bevel offline. Summary of the Invention

[0005] To address at least one of the aforementioned problems, the present invention first provides a fully automated photovoltaic module frame production line, comprising: at least one first frame production line and at least one second frame production line; the first frame production line includes, sequentially arranged along the conveying direction: a first steel strip feeding station, a first steel strip joining station, a first material storage buffer station, a first leveling station, a first front punching station, a first forming station, a first rear punching station, and a first cutting station; the first cutting station includes: at least one guide channel for continuous strip material to pass through and at least two relatively inclined cutters; the cutters are obliquely intersecting the extending direction of the guide channel. The system is configured to simultaneously cut continuous strip materials to a fixed length online and to form beveled edges at the ends. The first front punching station is used to punch holes in the surface of the continuous strip material to form two first process slots and at least one second process slot. The two first process slots extend along the width direction of the continuous strip material and correspond to the two cutters respectively, and are used to guide the two cutters to cut the continuous strip material along the first process slots. The second process slot extends along the width direction of the continuous strip material and is located between the two first process slots, and is used to provide deformation space for the waste material when the two cutters cut the continuous strip material.

[0006] Preferably, the fully automated photovoltaic module frame production line further includes a central control system, which is communicatively connected to the first steel strip docking station, the first material storage buffer station, the first front punching station, the first rear punching station, and the first cutting station. The central control system is configured to: dynamically adjust the running speed of the first steel strip feeding station and the first leveling station according to the real-time material storage volume of the first material storage buffer station; and control the running speed of the first rear punching station and the first cutting station to keep them synchronized with the steel strip according to the running speed of the first front punching station. The first cutting station is equipped with two position detection devices. The two position detection devices are respectively aligned with the passage paths of the two first process slots. When both position detection devices detect the first process slots, the central control system controls the two cutters to cut.

[0007] Preferably, downstream of the first cutting station are sequentially provided a first riveting station, a first corner code station, a first stacking station, and a first packaging station.

[0008] Preferably, the first frame production line further includes a cleaning station located between the first forming station and the first post-punching station, for cleaning and drying residual grease and debris from the previous process; the cleaning station includes, in sequence along the conveying direction, a high-pressure spray degreasing device, a water washing device, and an air knife drying device.

[0009] Preferably, the first frame production line further includes a coding station; the coding station is located between the cleaning station and the first post-punching station, or between the first post-punching station and the first cutting station; the coding station includes a coding machine for spraying traceability codes onto the surface of the first frame.

[0010] Preferably, the second frame production line is used to produce short frames, and includes, arranged sequentially along the conveying direction, a second steel strip feeding station, a second steel strip butt welding station, a second material storage buffer station, a second leveling station, a second front punching station, a second forming station, a second rear punching station, a second cutting station, a second riveting station, a second corner code station, a second stacking station, and a second packaging station; wherein, the second front punching station and the second rear punching station are respectively equipped with punching dies adapted to the hole positions of the short frame, and the second cutting station is configured to perform fixed-length cutting adapted to the length of the short frame; the first frame production line is used to produce long frames.

[0011] Preferably, the first steel strip unloading station includes an unloading rack; the unloading rack has at least a first roll position and a second roll position; the first roll position is used to release the steel strip, and the second roll position is used to prepare materials in advance to achieve roll changing without stopping the machine.

[0012] Preferably, the first steel strip butt welding station includes a shearing and welding machine, including a shearing mechanism for trimming the tail of the old roll and the head of the new roll, an alignment mechanism for aligning the old roll and the new roll, and a welding mechanism for welding the old roll and the new roll.

[0013] Preferably, a positioning guide bracket is provided between the feeding rack and the shearing and welding machine for positioning, guiding and conveying the steel strip released by the feeding rack to the shearing and welding machine.

[0014] Preferably, the first storage buffer station includes a spiral looper for storing a portion of the steel strip conveyed by the first steel strip docking station, and for continuing to supply steel strip to downstream stations while the first steel strip docking station is in operation.

[0015] Preferably, the first leveling station includes a leveling roller group and a transition idler roller arranged sequentially along the conveying direction; the leveling roller group includes multiple pairs of oppositely arranged rollers for leveling the steel strip output from the first storage buffer station and conveying it to the transition idler roller; the transition idler roller is a lifting idler roller, located between the discharge end of the leveling roller group and the feed end of the first front punching station.

[0016] Preferably, the first cutting station further includes: a guide seat, wherein the guide channel is disposed within the guide seat and extends along the conveying direction; the guide seat is broken at the extension path of the guide channel to form a break, for exposing the continuous strip material for punching; the break has two opposing inclined surfaces; the inclined surfaces are set at an angle to the extension direction of the guide channel.

[0017] Preferably, the two cutters are disposed on opposite sides of the cut and can reciprocate along the inclined plane; the fully automated photovoltaic module frame production line further includes a second drive device; the second drive device is connected to the rear section of the cutter to drive the cutter to reciprocate cutting.

[0018] Preferably, the cutter has a blade; the blade has at least one concave chip-receiving space on one side for accommodating waste generated during punching.

[0019] Preferably, the fully automated production line for photovoltaic module frames further includes a chip removal mechanism, which includes a chip removal table; the chip removal table is movably disposed within the break and located below the continuous strip-shaped material to receive and discharge the waste.

[0020] Preferably, a preset distance is maintained between the lower edges of the two inclined surfaces to form a clearance space, which allows the two cutters to avoid each other when cutting the continuous strip material to its maximum stroke.

[0021] Preferably, the chip-receiving space is a groove formed in the cutting edge; at least one groove is provided and located on one or both sides of the cutting edge.

[0022] Preferably, the inner wall of the groove has an arc-shaped structure, which is used to guide at least a portion of the waste material back to the chip removal platform within the fracture.

[0023] Preferably, the chip removal platform has a supporting state and a waste discharge state; in the supporting state, the chip removal platform is located within the break and supports the continuous strip-shaped material below, providing support force in conjunction with the cutter; in the waste discharge state, the chip removal platform moves out of the break to discharge the waste material; the chip discharge mechanism further includes a first driving device connected to the chip removal platform to drive the chip removal platform to switch between the supporting state and the waste discharge state.

[0024] Preferably, the upper surface of the chip removal platform is inclined to one side to form a discharge slope; the outer side of the guide seat is provided with a waste channel that connects with the discharge slope.

[0025] Preferably, a stop is provided on the side of the discharge ramp away from the waste channel.

[0026] Preferably, the outer side of the guide seat is also provided with a baffle that is disposed opposite to the waste channel; the baffle extends along the movement direction of the chip removal table and the height of the baffle is higher than the discharge slope.

[0027] Preferably, the continuous strip material is a photovoltaic module frame; the cross-section of the guide channel is a multi-step shape adapted to the contour of the photovoltaic module frame, so as to limit the photovoltaic module frame around its entire circumference.

[0028] This invention also provides a fully automated production process for photovoltaic module frames, comprising the following steps: S1. Unloading Steps: Install the steel strip coil on the first steel strip unloading station and release the steel strip. Pull out the head of the steel strip manually or by a traction vehicle, and then pass it through the positioning guide bracket, the first steel strip docking station, and the spiral loop of the first material storage buffer station in sequence, and send it into the first leveling station. Start the leveling roller group of the first leveling station. The leveling roller group acts as the front pulling force to bite into the steel strip and continuously pull the steel strip to the first front punching station, and then enter the subsequent stations in sequence. The leveling roller group and the downstream first forming station continue to pull the steel strip, so that the steel strip is output from the spiral loop. At the same time, the speed of the first steel strip unloading station and the first leveling station is matched according to the real-time material storage of the spiral loop. S2. Leveling step: The steel strip output from the spiral looper of the first storage buffer station is fed into the leveling roller group of the first leveling station for leveling. S3. Punching step: The leveled steel strip is fed into the first front punching station through the transition roller for punching, and at least one specification of holes are punched out on the steel strip in sequence. S4. Continuous cold bending forming step: The punched steel strip is continuously fed into the first forming station to form the first frame. S5. Cutting step: Using the first cutting station, the continuous cylindrical products are cut to a fixed length according to a preset length and cut at an angle to obtain a single first frame. S6. Repeat steps S1-S5 above to obtain a single second border; Preferably, the fully automated production process for photovoltaic module frames also includes a welding step: After one roll of steel strip is used, the second roll is rotated to the position of the first roll and the steel strip is released through the coordination of the central control system. The head of the steel strip is pulled out manually or by a tractor and then conveyed through the positioning guide bracket to the first steel strip docking station. The tail of the old roll and the head of the new roll are then trimmed by a shearing and welding machine. After aligning the old roll and the new roll, the old roll and the new roll are welded together to achieve continuous supply of steel strip. At the same time, the central control system adjusts the feeding and leveling speed according to the material storage of the spiral looper to ensure continuous production.

[0029] 1. Compared with the prior art, the present invention sets up a first cutting station downstream of the first punching station that can simultaneously cut and bevel the edges, thereby enabling the photovoltaic module frame to be cut online directly after forming and beveled at the same time. In the prior art, the cutting is often performed first, and then the material is uniformly transported to the cutting station for bevel cutting. This lengthens the production line, increases the number of equipment, and requires secondary positioning when beveling, which is prone to inaccurate bevel cutting and deviation. Moreover, this offline mode of uniformly transporting the material to the cutting station for bevel cutting generates a high waste rate.

[0030] 2. Compared with the prior art, in this invention, two first process slots and at least one second process slot are punched on the surface of the steel strip through the first front punching station, and both process slots are located on the horizontal step in the middle of the first or second frame after forming. Firstly, the two first process slots can guide the two cutters to cut and form, reducing cutter wear. Moreover, pre-processing the two first process slots is equivalent to pre-setting the length, and the position of the bevel is accurate. Secondly, the second process slot is set between the two first process slots, which can provide deformation space for the waste material when the two cutters cut the first or second frame, thereby avoiding the waste material getting stuck and the two cutters getting stuck.

[0031] 3. Compared with the prior art, the present invention sets up the first frame production line and the second frame production line in parallel, and combines the overall control system to dynamically match the speed of the steel strip feeding station, leveling station, punching station and cutting station, and the spiral looper to achieve non-stop roll changing, which greatly reduces the downtime between processes, realizes multi-line synchronous production, and increases the output per unit time. It can produce both long and short frames of photovoltaic modules at the same time, and meet the production needs of large-scale photovoltaic module frames. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the overall structure of the first frame production line in this invention; Figure 2 for Figure 1 Structural diagram at point A; Figure 3 for Figure 1 Structural diagram at point B; Figure 4 for Figure 1 Structural diagram at point C; Figure 5 for Figure 1 Structural diagram at point D; Figure 6 for Figure 1 Structural diagram at point E; Figure 7 To and Figure 2 The corresponding top view; Figure 8To and Figure 3 The corresponding top view; Figure 9 To and Figure 4 The corresponding top view; Figure 10 To and Figure 5 The corresponding top view; Figure 11 To and Figure 6 The corresponding top view; Figure 12 This is a top view of the first cutting station; Figure 13 This is a front view of the first cutting station; Figure 14 This is a side view of the first cutting station; Figure 15 This is a structural diagram of the first process slot and the second process slot; Figure 16 This is a structural diagram of the first process slot after the steel strip is formed; Figure 17 This is a structural diagram showing the installation of the position detection device and the first process slot.

[0033] Explanation of reference numerals in the attached figures: 1-First steel strip feeding station; 2-First steel strip butt welding station; 3-First material storage buffer station; 4-First leveling station; 5-First front punching station; 6-First forming station; 7-First rear punching station; 8-First cutting station; 9-Positioning guide bracket; 10-Cleaning station; 11-Coding station; 12-Position detection device; 81-Guide seat; 82-Cutter; 83-Chip removal table; 84-Second drive device; 101-Feeding rack; 102-First winding position; 103 - Second roll position; 201-Shearing and welding machine; 301-Spiral looper; 401-Leveling roller group; 402-Transition idler roller; 501-First process slot; 502-Second process slot; 701-Punching equipment; 8101-Guide channel; 8102-Break; 8103-Inclined surface; 8104-Baffle; 8201-Cutting edge; 8202-Chip space; 8301-Discharge inclined surface; 8302-Waste channel; 8303-Stop; 8304-First drive device. Detailed Implementation

[0034] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0035] In the description of this invention, it should be understood that the terms "upper" and "lower" indicate the orientation or positional relationship based on the orientation or positional relationship when the product is in normal use.

[0036] 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.

[0037] Please see Figure 1-3 As shown, the present invention provides a fully automated production line for photovoltaic module frames, comprising: at least one first frame production line and at least one second frame production line; the first frame production line includes, sequentially arranged along the conveying direction: a first steel strip feeding station 1, a first steel strip docking station 2, a first material storage buffer station 3, a first leveling station 4, a first front punching station 5, a first forming station 6, a first rear punching station 7, and a first cutting station 8; the first cutting station 8 includes: at least one guide channel 8101 through which continuous strip-shaped material can pass and at least two relatively inclined cutters 82; the cutters 82 are obliquely arranged with the extension direction of the guide channel 8101 to perform online synchronous fixed-length cutting of continuous strip-shaped material and end bevel forming; the first front punching station 5 is used to punch holes on the surface of the continuous strip-shaped material and form two first process slots 501 and At least one second process slot 502; two first process slots 501 extend along the width direction of the continuous strip material and correspond to two cutters 82 respectively, for guiding the two cutters 82 to cut the continuous strip material along the first process slots 501; the second process slot 502 extends along the width direction of the continuous strip material and is located between the two first process slots 501, for providing deformation space for the waste material when the two cutters 82 cut the continuous strip material; thus, online cutting and simultaneous beveling can be achieved; while in the existing technology, cutting is often performed first, and then uniformly conveyed to the cutting station for beveling, which lengthens the production line, increases the number of equipment, and requires secondary positioning when beveling, which is prone to inaccurate beveling and deviation; moreover, the waste rate generated by this offline mode of uniformly conveying to the cutting station for beveling is higher than that of the present invention. Specifically, traditional offline beveling easily leads to increased waste, explained as follows: Firstly, during secondary positioning, the cutting process requires clamping space and machining allowance. In offline beveling, the beveling machine's clamps must hold the end of the profile before sawing. To ensure the beveling saw blade doesn't cut the clamps and that the clamps can hold them securely, the length of the photovoltaic module frame must be longer than the final product length during flat cutting. This extra section, which should be good material, is cut off as waste during beveling. Secondly, secondary positioning may cause beveling deviation, leading to an increased defect rate and resulting in some photovoltaic module frames being scrapped. Figure 1 In the diagram, A, B, C, D, and E represent the structure and specific devices of each part of the first frame production line.

[0038] Regarding the setting of the first process slot 501 and the second process slot 502: The continuous strip material is a steel strip, and the first process slot 501 and the second process slot 502 are processed on the steel strip. The shape and size of the first process slot 501 and the second process slot 502 can be set to be the same or different. For example, the two first process slots 501 and the second process slots 502 are arranged side by side, and their shapes and sizes are the same and they are arranged at equal intervals. This can reduce the difficulty of punching and eliminate the need to use multiple different punches. The purpose of this setup is as follows: The two first process slots 501 serve two purposes: First, to achieve pre-punching: By punching a portion of the trajectory line to be cut through in advance through the first pre-punching station 5, forming the first process slot 501, the path that originally required the cutter 82 to cut through the solid material has been partially hollowed out in advance; Second, to guide the cutting path, specifically by providing a cutting notch: The cutter 82 and the first process slots 501 are correspondingly set. During cutting, the blade 8201 of the cutter 82 will first pass through the side wall of the formed first frame (i.e., Figure 16 The vertical section at the upper right), and then cut into the middle horizontal step (i.e. Figure 16 (In the middle horizontal section), at this time, the cutting edge 8201 of the cutter 82 reaches the first process slot 501 of the step. The first process slot 501 provides a precise entry point for the cutting edge 8201 of the cutter 82, guiding the cutter 82 to continue cutting in. During the process of the cutter 82 passing through the first process slot 501, the two side walls of the first process slot 501 at the front and rear of the cutter 82 form a limiting constraint on the cutter 82, reducing the deviation of the cutter 82 in the length direction of the continuous strip material. In summary, after cutting the side wall of the first frame, the cutter 82 continues to move diagonally downward along the existing first process slot 501. The inner wall of the first process slot 501 naturally becomes the guide rail of the cutter 82, limiting the deviation of the cutter 82 in the length direction and ensuring that the cutting line is straight. The purpose of the second process slot 502 is to facilitate the stress release of the waste material and provide deformation clearance space: when the two cutters 82 cut downward at the same time, the material between the two cutting lines, i.e., the waste material, is forced to separate from the parent material. If the material between the two first process slots 501 is solid, the waste will have nowhere to go at the moment of cutting, which will generate great compressive stress and may cause the cutter 82 to jam. The second process slot 502 set between the two first process slots 501 is equivalent to pre-drilling a cavity in the waste. When the cutters 82 on both sides cut in, the waste strip in the middle can deform into the gap of the second process slot 502 after being stressed, such as bending or collapsing, thereby releasing the internal stress at the moment of cutting.

[0039] In one embodiment, such as Figure 9As shown, after the first or second frame is continuously cold-bent, the first process slot 501 and the second process slot 502 are located on a horizontal step in the middle of the formed first or second frame, extending along the width of the step. On one hand, the step provides a relatively ideal force-bearing plane for the cutter 82, ensuring the dimensional accuracy of the slot and reducing wear on the cutter 82. If the first process slot 501 and the second process slot 502 are located on the outer surface of the formed first frame, dents may occur during corner cutting, affecting the appearance quality. If they are located on the back plate of the first frame, the scrap on the back plate cannot fall downwards after being cut, easily leading to material blockage and cutter jamming. On the other hand, when the cutter 82 cuts along the first process slot 501, the scrap located between the two tangents can retreat to the second process slot 502 via the shortest horizontal path, avoiding scrap jamming or profile cross-section distortion, while not affecting the appearance quality and overall structural strength of the first or second frame. The first process slot 501 and the second process slot 502 preferably use through slots.

[0040] The fully automated photovoltaic module frame production line also includes a central control system, which is communicatively connected to the first steel strip docking station 2, the first material storage buffer station 3, the first front punching station 5, the first rear punching station 7, and the first cutting station 8. The central control system is configured to: dynamically adjust the running speed of the first steel strip feeding station 1 and the first leveling station 4 according to the real-time material storage volume of the first material storage buffer station 3; and control the running speed of the first rear punching station 7 and the first cutting station 8 to keep them synchronized with the steel strip according to the running speed of the first front punching station 5. The first cutting station 8 is equipped with two position detection devices 12. The two position detection devices 12 are respectively aligned with the passage paths of the two first process slots 501. When both position detection devices 12 detect the first process slots 501, the central control system controls the two cutters 82 to cut. The specific principle is as follows: By setting up at least one first frame production line and at least one second frame production line in parallel, long and short frames of photovoltaic modules can be produced simultaneously. The central control system connects each key station via communication, dynamically adjusting the running speed of the first steel strip feeding station 1 and the first leveling station 4 according to the real-time material storage of the spiral looper 301. It also controls the first rear punching station 7 and the first cutting station 8 to keep synchronized with the steel strip based on the reference hole position signal of the first front punching station 5, ensuring process coordination. Multi-line parallel operation can improve efficiency; the central control system achieves speed matching and synchronous control of each station, avoiding manual intervention and ensuring production continuity and product consistency. Downstream of the first cutting station 8, there are also a first riveting station, a first corner code station, a first stacking station, and a first packaging station, used for riveting, corner code installation, and stacking, respectively. The spiral looper 301 can refer to the spiral looper structure in patent CN204769902U, or refer to the spiral loopers in existing technologies, to achieve buffering of materials such as steel strips. Spiral loopers 301 are generally available in horizontal and vertical types. This application uses a vertical spiral looper for easier material feeding.

[0041] Regarding the configuration of the position detection device 12: When the continuous strip material moves during the conveying process, the two first process slots 501 move forward synchronously. When the two first process slots 501 reach directly below the two position detection devices 12: the first position detection device 12 detects the first first process slot 501; the second position detection device 12 detects the second first process slot 501. Both position detection devices 12 simultaneously output detection signals to the central control system. Based on these signals, the central control system determines that the two first process slots 501 have accurately reached the preset detection positions. Since the relative positions of the two position detection devices 12 and the two cutters 82 are fixed, the central control system can immediately, or after a short delay, control the two cutters 82 to perform a cutting action, ensuring that the cutters 82 accurately cut the material along the first process slots 501.

[0042] Please see Figure 1As shown, in one embodiment, the first frame production line further includes a cleaning station 10, located between the first forming station 6 and the first post-punching station 7, for cleaning and drying residual grease and debris from previous processes. The cleaning station 10 includes, sequentially arranged along the conveying direction, a high-pressure spray degreasing device, a water washing device, and an air knife drying device. By setting the cleaning station 10 between the first forming station 6 and the first post-punching station 7, residual grease and debris from the forming process are removed and dried using the high-pressure spray degreasing device, the water washing device, and the air knife drying device. This prevents contaminants from affecting the post-punching accuracy and product surface quality, improving the cleanliness of the frame.

[0043] Please see Figure 1 As shown, in one embodiment, the first frame production line further includes a coding station 11; the coding station 11 is located between the cleaning station 10 and the first post-punching station 7, or between the first post-punching station 7 and the first cutting station 8; the coding station 11 includes a coding machine for spraying traceability codes onto the surface of the first frame. The coding station 11 is located between the cleaning station 10 and the first post-punching station 7, or between the first post-punching station 7 and the first cutting station 8; the coding station 11 includes a coding machine for spraying traceability codes onto the surface of the first frame. This facilitates product quality traceability and management, and improves production traceability.

[0044] The second frame production line is used to produce short frames and includes, sequentially arranged along the conveying direction, the following stations: second steel strip feeding station, second steel strip butt welding station, second material storage and buffer station, second leveling station, second front punching station, second forming station, second rear punching station, second cutting station, second riveting station, second corner code station, second stacking station, and second packaging station. The second front punching station and the second rear punching station are each equipped with punching dies adapted to the hole positions of the short frames, and the second cutting station is configured with a fixed-length cutting tool adapted to the length of the short frames. The first frame production line is used to produce long frames. This meets the production needs of both long and short frames for large-scale photovoltaic modules. If only long frames or only short frames are to be produced, one production line is sufficient; if both long and short frames are to be produced simultaneously, using two separate production lines can improve production efficiency.

[0045] Please see Figure 1As shown, in one embodiment, the first steel strip unloading station 1 includes an unloading rack 101; the unloading rack 101 has at least a first winding position 102 and a second winding position 103; the first winding position 102 is used to release the steel strip, and the second winding position 103 is used to prepare materials in advance to achieve uninterrupted winding. The unloading station 1 includes an unloading rack 101; the unloading rack 101 has at least a first winding position 102 and a second winding position 103; the first winding position 102 is used to release the steel strip, and the second winding position 103 is used to prepare materials in advance to achieve uninterrupted winding. Winding changes can be completed without stopping the production line, avoiding downtime losses caused by winding changes and improving production continuity.

[0046] Please see Figure 1 As shown, in one embodiment, the first steel strip butt welding station 2 includes a shearing and welding machine 201, comprising a shearing mechanism for trimming the tail of the old coil and the head of the new coil, an alignment mechanism for aligning the old coil and the new coil, and a welding mechanism for welding the old coil and the new coil together. The shearing and welding machine 201 can adopt the shearing and welding machine structure in patent CN209716847U, or existing shearing and welding devices for steel strip butt welding, to achieve the cutting of the first and last ends of the steel strip and the welding of the two coils together, replacing manual welding, reducing human error, improving the efficiency and quality of steel strip butt welding, and ensuring continuous supply of steel strip.

[0047] Please see Figure 1 As shown, in one embodiment, a positioning guide bracket 9 is provided between the feeding rack 101 and the shearing and welding machine 201. This positioning guide bracket 9 is used to position, guide, and convey the steel strip released from the feeding rack 101 to the shearing and welding machine 201. The positioning guide bracket 9 ensures the stability of the steel strip conveying and reduces equipment failures or product quality problems caused by steel strip misalignment.

[0048] Please see Figure 1 As shown, in one embodiment, the first storage buffer station 3 includes a spiral looper 301 for storing a portion of the steel strip conveyed by the first steel strip docking station 2, and continuing to supply steel strip to downstream stations while the first steel strip docking station 2 is operating. This ensures a continuous supply of steel strip to downstream stations, achieving uninterrupted production and improving production line stability.

[0049] Please see Figure 1As shown, in one embodiment, the first leveling station 4 includes a leveling roller group 401 and a transition idler roller 402 arranged sequentially along the conveying direction. The leveling roller group 401 includes multiple pairs of opposing rollers for leveling the steel strip output from the first storage buffer station 3 and conveying it to the transition idler roller 402. The transition idler roller 402 is a lifting idler roller, located between the discharge end of the leveling roller group 401 and the feed end of the first front punching station 5. The leveling station 4 includes a leveling roller group 401 and a transition idler roller 402 arranged sequentially along the conveying direction. The leveling roller group 401 includes multiple pairs of opposing rollers for leveling the steel strip output from the storage buffer station 3 and conveying it to the transition idler roller 402. The transition idler roller 402 can be a lifting idler roller, located between the discharge end of the leveling roller group 401 and the feed end of the front punching station 5, providing a stable flat substrate for subsequent punching and forming, and improving processing accuracy.

[0050] Please see Figure 1 As shown, in one embodiment, the first pre-punching station 5 includes at least one first punch for punching mounting slots and at least one second punch for punching grounding holes. Pre-completing the machining of critical holes provides a positioning reference for the synchronous movement of the first post-punching station 7 and the first cutting station 8, improving punching accuracy and production coordination. In one embodiment, the first post-punching station 7 includes multiple punching devices 701. The first post-punching station 7 includes multiple punching devices 701, each used to punch different holes.

[0051] Please see Figure 1 As shown, in one embodiment, the first forming station 6 includes a plurality of forming roller groups arranged sequentially along the conveying direction; at least one forming roller group is connected to a power source; the power source includes, but is not limited to, an electric motor. This is used to gradually roll a straight steel strip into a target frame cross-section.

[0052] Please see Figure 5-7 As shown, in one embodiment, the first cutting station 8 further includes: a guide seat 81, a guide channel 8101 disposed within the guide seat 81 and extending along the conveying direction; the guide seat 81 is broken on the extension path of the guide channel 8101 to form a break 8102 for exposing continuous strip-shaped material for punching; the break 8102 has two opposing inclined surfaces 8103; the inclined surfaces 8103 are set at an angle to the extension direction of the guide channel 8101, thereby enabling continuous cutting and beveling.

[0053] Please see Figure 5-7As shown, in one embodiment, two cutters 82 are respectively disposed on opposite sides of the cut 8102 and can reciprocate along the inclined surface 8103; the fully automated photovoltaic module frame production line also includes a second drive device 84; the second drive device 84 is connected to the rear section of the cutter 82 to drive the cutter 82 to reciprocate cutting, thereby enabling continuous cutting and beveling.

[0054] Please see Figure 5-7 As shown, in one embodiment, the cutter 82 has a blade 8201; the blade 8201 has at least one concave chip space 8202 on one side for accommodating waste generated during punching and preventing material jamming.

[0055] Please see Figure 5-7 As shown, in one embodiment, the fully automated production line for photovoltaic module frames further includes a chip removal mechanism, which includes a chip removal table 83. The chip removal table 83 is movably disposed within the break 8102 and located below the continuous strip of material to receive and discharge waste.

[0056] Please see Figure 5-7 As shown, in one embodiment, a preset distance is maintained between the lower edges of the two inclined surfaces 8103 to form a clearance space, which is used for the two cutters 82 to avoid each other when cutting continuous strip-shaped materials to their maximum stroke. If the two cutters 82 are completely closed at the maximum stroke, the blade tips are very likely to collide hard and break. In this embodiment, by setting a clearance space, a gap is still left between the blades 8201 of the two cutters when they reach the bottom, which avoids the blade tips colliding and causing damage, and makes the waste form a trapezoidal structure that is wider at the top and narrower at the bottom. This trapezoidal waste is easy to discharge and reduces material jamming.

[0057] Please see Figure 5-7 As shown, in one embodiment, the chip-receiving space 8202 is a groove formed in the cutting edge 8201; at least one groove is provided and located on one or both sides of the cutting edge 8201. When there are two grooves and they are respectively located on both sides of the cutting edge 8201, they can be symmetrically arranged. During the punching process, the two edges of the waste can travel along the inner wall of the groove, ensuring that the waste can fall back onto the chip-receiving platform 83 below when the blade is retracted; if the chip-receiving space 8202 is not provided, the waste during the punching process is easy to get stuck above the cutter 82 and is not easy to be discharged.

[0058] Please see Figure 5-7As shown, in one embodiment, the inner wall of the groove is an arc-shaped structure to guide at least a portion of the waste material back onto the chip removal platform 83 within the break 8102. If the inner wall of the groove is a right angle or has sharp edges, the waste material is easily hooked at the right angle after being squeezed in and is difficult to detach. In this embodiment, the inner wall of the groove is set as an arc-shaped structure, eliminating dead angles in chip removal. When the cutter 82 retracts, the arc-shaped inner wall is equivalent to a smooth slip surface. Under the combined action of gravity and the guiding effect of the arc surface, the waste material easily slides and detaches along the arc-shaped inner wall, smoothly falling back onto the chip removal platform 83 and then being discharged.

[0059] Please see Figure 5-7 As shown, in one embodiment, the chip removal table 83 has a supporting state and a waste discharge state. In the supporting state, the chip removal table 83 is located within the cut 8102 and supports the continuous strip-shaped material below, providing support force in conjunction with the cutter 82. In the waste discharge state, the chip removal table 83 moves out of the cut 8102 to discharge waste material. The chip discharge mechanism also includes a first driving device 8304 connected to the chip removal table 83 to drive the chip removal table 83 to switch between the supporting state and the waste discharge state. For thin-walled profiles such as photovoltaic module frames, if the area below the cut 8102 is suspended, the profile is prone to instability and denting when the cutter 82 presses down, resulting in poor cut surface quality. This embodiment enables the chip removal table 83 to have two functions: during punching, the chip removal table 83 is in a supporting state to provide a certain rigid support for the profile and reduce deformation, especially when the surface of the chip removal table 83 is horizontal; after punching is completed, the first driving device 8304 drives it to switch to the waste discharge state to transport the received waste material out of the cut 8102; the first driving device 8304 includes, but is not limited to, a cylinder and an electric telescopic rod.

[0060] Please see Figure 5-7 As shown, in one embodiment, the upper surface of the chip removal table 83 is inclined to one side to form a discharge ramp 8301; a waste channel 8302 is provided on the outer side of the guide seat 81, which connects with the discharge ramp 8301. After the chip removal table 83 transports the waste out of the break 8102, the waste needs to be peeled off from the table surface. In this embodiment, by setting the discharge ramp 8301, when the chip removal table 83 extends out of the break 8102, the waste automatically slides down the discharge ramp 8301 to the waste channel 8302 under the action of gravity, realizing automatic unloading and collection of waste. There is no need to set up additional scrapers or push rods to clean the chip removal table 83.

[0061] Please see Figure 5-7As shown, in one embodiment, a stop 8303 is provided on the side of the discharge ramp 8301 away from the waste channel 8302 to stop the waste from running back when the chip table 83 moves, thus preventing some waste from remaining on the discharge ramp 8301 and not entering the waste channel 8302, or from being discharged in other directions. Because the chip table 83 accelerates and extends under the drive of the first drive device 8304, the waste tends to remain in its original position due to inertia, i.e., run back, which may cause the waste to scatter from the other side of the chip table 83. A stop 8303 is provided on the rear side of the discharge ramp 8301. During the movement of the chip table 83, the stop 8303 blocks the waste from behind, forcing the waste to move forward with the chip table 83.

[0062] Please see Figure 5-7 As shown, in one embodiment, a baffle 8104 is also provided on the outside of the guide seat 81, which is opposite to the waste channel 8302. The baffle 8104 extends along the movement direction of the chip removal table 83 and the height of the baffle 8104 is higher than the discharge slope 8301, so as to prevent the waste from falling from other directions and not entering the waste channel 8302 to be collected.

[0063] Please see Figure 5-7 As shown, in one embodiment, the continuous strip material is the photovoltaic module frame; the cross-section of the guide channel 8101 is a multi-step shape adapted to the contour of the photovoltaic module frame to limit the photovoltaic module frame around its entire circumference. The photovoltaic module frame is an asymmetrical, complex, thin-walled profile. If only partially limited, it is prone to twisting or shifting when subjected to lateral punching force. Ensuring good rigidity of the photovoltaic module frame during punching prevents it from being easily punched into indentations, thereby cutting a higher quality bevel angle.

[0064] This invention also provides a fully automated production process for photovoltaic module frames, comprising the following steps: S1. Unloading Steps: The steel strip coil is installed on the first steel strip unloading station 1, and the steel strip is released. The head of the steel strip is pulled out manually or by a traction vehicle, and then passes through the spiral looper 301 of the positioning guide bracket 9, the first steel strip docking station 2, and the first material storage buffer station 3 in sequence, and is sent into the first leveling station 4; the leveling roller group 401 of the first leveling station 4 is started, and the leveling roller group 401 acts as the front pulling force to bite into the steel strip, continuously pulling the steel strip to the first front punching station 5, and then into the subsequent stations in sequence; the leveling roller group 401 and the downstream first forming station 6 continue to pull the steel strip, so that the steel strip is output from the spiral looper 301. At the same time, the speed of the first steel strip unloading station 1 and the first leveling station 4 is matched according to the real-time material storage of the spiral looper 301; a continuous material supply state of the production line is established to realize automatic steel strip conveying and provide stable input for subsequent processes; S2, Leveling step: The steel strip output from the spiral looper 301 of the first material storage buffer station 3 is fed into the leveling roller group 401 of the first leveling station 4 for leveling; to improve the straightness of the steel strip, provide stress-free substrate for punching and forming, and improve the accuracy of subsequent processing. S3. Punching step: The leveled steel strip is fed into the first front punching station 5 through the transition roller 402 for punching, and at least one specification of holes are punched out on the steel strip in sequence; the key hole processing is completed in advance to provide a positioning reference for the synchronous follow-up of the first rear punching station 7 and the first cutting station 8, and to ensure the consistency of punching. S4. Continuous cold bending forming step: The punched steel strip is continuously fed into the first forming station 6 to form the first frame. S5. Cutting step: Using the first cutting station 8, the continuous cylindrical products are cut to a fixed length according to a preset length and cut at an angle to obtain a single first frame. S6. Repeat steps S1-S5 above to obtain a single second border; The process also includes a welding step: After one roll of steel strip is used, the second roll position 103 is rotated to the first roll position 102 and the steel strip is released through the overall control system. The head of the steel strip is then pulled out manually or by a tractor and transported sequentially through the positioning guide bracket 9 to the first steel strip docking station 2. The tail of the old roll and the head of the new roll are then trimmed by the shearing and welding machine 201. After aligning the old and new rolls, they are welded together, achieving continuous supply of steel strip. At the same time, the overall control system adjusts the feeding and leveling speed according to the material storage of the spiral looper 301 to ensure continuous production. This achieves true non-stop continuous production, improving capacity and material utilization.

[0065] While the disclosure is as stated above, its scope of protection is not limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of this disclosure, and all such changes and modifications will fall within the protection scope of this invention.

Claims

1. A fully automated production line for photovoltaic module frames, characterized in that, include: At least one first-frame production line and at least one second-frame production line; The first frame production line includes the following stations arranged in sequence along the conveying direction: first steel strip feeding station (1), first steel strip docking station (2), first material storage buffer station (3), first leveling station (4), first front punching station (5), first forming station (6), first rear punching station (7), and first cutting station (8). The first cutting station (8) includes: at least one guide channel (8101) through which continuous strip material can pass and at least two relatively inclined cutters (82); the cutters (82) are obliquely arranged with respect to the extension direction of the guide channel (8101) so as to perform fixed-length cutting and end bevel forming of the continuous strip material online synchronously; The first front punching station (5) is used to punch holes in the surface of the continuous strip material to form two first process slots (501) and at least one second process slot (502); the two first process slots (501) extend along the width direction of the continuous strip material and correspond to the two cutters (82) respectively, and are used to guide the two cutters (82) to cut the continuous strip material and form bevels along the first process slots (501) respectively; the second process slot (502) extends along the width direction of the continuous strip material and is located between the two first process slots (501), and is used to provide deformation space for the waste material when the two cutters (82) cut the continuous strip material; It also includes the central control system; The first cutting station (8) is equipped with two position detection devices (12); The second frame production line is used to produce short frames and includes, in sequence along the conveying direction, a second steel strip feeding station, a second steel strip butt welding station, a second material storage and buffer station, a second leveling station, a second front punching station, a second forming station, a second rear punching station, a second cutting station, a second riveting station, a second corner code station, a second stacking station, and a second packaging station; wherein, the second front punching station and the second rear punching station are respectively equipped with punching dies adapted to the hole positions of the short frame, and the second cutting station is configured with a fixed-length cutting adapted to the length of the short frame; the first frame production line is used to produce long frames.

2. The fully automated production line for photovoltaic module frames according to claim 1, characterized in that, The overall control system is connected to the first steel strip docking station (2), the first material storage buffer station (3), the first front punching station (5), the first rear punching station (7), and the first cutting station (8) respectively. The overall control system is configured to: dynamically adjust the running speed of the first steel strip feeding station (1) and the first leveling station (4) according to the real-time material storage of the first material storage buffer station (3), and control the running speed of the first rear punching station (7) and the first cutting station (8) to keep them synchronized with the steel strip according to the running speed of the first front punching station (5). The two position detection devices (12) are respectively aligned with the passage paths of the two first process slots (501); when both position detection devices (12) detect the first process slots (501), the main control system controls the two cutters (82) to cut.

3. The fully automated production line for photovoltaic module frames according to claim 2, characterized in that, The first frame production line also includes a cleaning station (10), located between the first forming station (6) and the first post-punching station (7), for cleaning and drying the grease and debris remaining in the previous process; the cleaning station (10) includes, in sequence along the conveying direction: a high-pressure spray degreasing device, a water washing device and an air knife drying device. And / or, the first frame production line further includes a coding station (11); the coding station (11) is located between the cleaning station (10) and the first post-punching station (7), or between the first post-punching station (7) and the first cutting station (8).

4. The fully automated production line for photovoltaic module frames according to claim 1, characterized in that, The first steel strip feeding station (1) includes a feeding rack (101); the feeding rack (101) has at least a first roll position (102) and a second roll position (103).

5. The fully automated production line for photovoltaic module frames according to claim 4, characterized in that, The first steel strip butt welding station (2) includes a shearing and welding machine (201), including a shearing mechanism for trimming the tail of the old roll and the head of the new roll, an alignment mechanism for aligning the old roll and the new roll, and a welding mechanism for welding the old roll and the new roll. And / or, a positioning guide bracket (9) is provided between the feeding rack (101) and the shearing and welding machine (201) for positioning, guiding and conveying the steel strip released by the feeding rack (101) to the shearing and welding machine (201).

6. The fully automated production line for photovoltaic module frames according to claim 1, characterized in that, The first material storage buffer station (3) includes a spiral looper (301) for storing part of the steel strip conveyed by the first steel strip docking station (2) and continuing to supply steel strip to the downstream station when the first steel strip docking station (2) is working; And / or, the first leveling station (4) includes a leveling roller group (401) and a transition roller (402) arranged sequentially along the conveying direction; the leveling roller group (401) includes multiple pairs of oppositely arranged rollers for leveling the steel strip output from the first storage buffer station (3) and conveying it to the transition roller (402); the transition roller (402) is a lifting roller, located between the discharge end of the leveling roller group (401) and the feed end of the first front punching station (5).

7. The fully automated production line for photovoltaic module frames according to claim 1, characterized in that, The first cutting station (8) further includes: a guide seat (81), wherein the guide channel (8101) is disposed in the guide seat (81) and extends along the conveying direction; the guide seat (81) is broken on the extension path of the guide channel (8101) to form a break (8102) for exposing the continuous strip material for punching; the break (8102) has two oppositely arranged inclined surfaces (8103); the inclined surfaces (8103) are obliquely arranged to the extension direction of the guide channel (8101); And / or, the two cutters (82) are respectively located on opposite sides of the cut (8102) and can reciprocate along the inclined surface (8103); the fully automatic production line for photovoltaic module frames also includes a second drive device (84); the second drive device (84) is connected to the rear section of the cutter (82) to drive the cutter (82) to reciprocate cutting.

8. The fully automated production line for photovoltaic module frames according to claim 7, characterized in that, The cutter (82) has a blade (8201); the blade (8201) has a concave chip-receiving space (8202) on at least one side for accommodating waste generated during punching; And / or, the fully automated production line for photovoltaic module frames further includes a chip removal mechanism, which includes a chip removal table (83); the chip removal table (83) is movably disposed within the break (8102) and located below the continuous strip material to receive and discharge the waste material; And / or, a preset distance is maintained between the lower edges of the two inclined surfaces (8103) to form a clearance space, which is used for the two cutters (82) to avoid each other when cutting the continuous strip material to the maximum stroke; And / or, the chip-receiving space (8202) is a groove formed in the cutting edge (8201); at least one groove is provided and located on one or both sides of the cutting edge (8201); And / or, the inner wall of the groove is an arc-shaped structure, used to guide at least a portion of the waste material back to the chip removal platform (83) within the break (8102); And / or, the chip removal table (83) has a support state and a waste discharge state; in the support state, the chip removal table (83) is located within the cut (8102) and supported below the continuous strip material, providing support force in conjunction with the cutter (82); in the waste discharge state, the chip removal table (83) moves out of the cut (8102) to discharge the waste material; the chip removal mechanism also includes a first drive device (8304) connected to the chip removal table (83) to drive the chip removal table (83) to switch between the support state and the waste discharge state.

9. A fully automated production line for photovoltaic module frames according to claim 8, characterized in that, The upper surface of the chip removal table (83) is inclined to one side to form a discharge slope (8301); the outer side of the guide seat (81) is provided with a waste channel (8302) that connects with the discharge slope (8301). And / or, a stop (8303) is provided on the side of the discharge ramp (8301) away from the waste channel (8302). And / or, the outer side of the guide seat (81) is also provided with a baffle (8104) that is opposite to the waste channel (8302); the baffle (8104) extends along the movement direction of the chip table (83) and the height of the baffle (8104) is higher than the discharge ramp (8301). And / or, the continuous strip material is a photovoltaic module frame; the cross-section of the guide channel (8101) is a multi-step shape adapted to the outline of the photovoltaic module frame, so as to limit the photovoltaic module frame around its entire circumference.

10. A fully automated production process for photovoltaic module frames, employing the fully automated production line for photovoltaic module frames as described in claim 9, characterized in that, Includes the following steps: S1. Unloading steps: Install the steel strip roll on the first steel strip unloading station (1) and release the steel strip. Pull out the head of the steel strip manually or by traction vehicle, and then pass through the spiral loop (301) of the positioning guide bracket (9), the first steel strip docking station (2), and the first material storage buffer station (3) in sequence, and send it into the first leveling station (4); start the leveling roller group (401) of the first leveling station (4), and use the leveling roller group (401) as the front pulling power to bite into the steel strip, and continuously pull the steel strip to the first front punching station (5), and then enter the subsequent stations in sequence; the leveling roller group (401) and the downstream first forming station (6) continuously pull the steel strip, so that the steel strip is output from the spiral loop (301). At the same time, the first steel strip unloading station (1) and the first leveling station (4) match the speed according to the real-time material storage of the spiral loop (301); S2, Leveling step: The steel strip output from the spiral loop (301) of the first storage buffer station (3) is fed into the leveling roller group (401) of the first leveling station (4) for leveling. S3, punching step: The leveled steel strip is fed into the first front punching station (5) through the transition roller (402) for punching, and at least one specification of holes are punched out on the steel strip in sequence. S4. Continuous cold bending forming step: The punched steel strip is continuously fed into the first forming station (6) to form the first frame; S5. Cutting step: Using the first cutting station (8), the continuous cylindrical products are cut to a fixed length according to the preset length and cut at an angle to obtain a single first frame.

Images