A soldering device for a photovoltaic module

Abstract

This application relates to the field of photovoltaic module manufacturing equipment technology, and provides a welding device for photovoltaic modules, comprising: a pressing module including two pressure plates arranged side by side along a first horizontal direction, and a lifting drive mechanism for driving the pressure plates to rise and fall, wherein the bottom of the pressure plates is provided with a clearance groove; a solder strip straightening module connected to the lifting drive mechanism, comprising: two straightening modules arranged opposite each other, each straightening module having a plurality of straightening rods arranged on the side facing the other straightening module; within the same straightening module, the spacing between adjacent straightening rods is sufficient to accommodate the embedding of a straightening rod from the other straightening module, and the ends of the straightening rods of the two straightening modules can be moved to the space between the two pressure plates; and a driving module for driving the straightening modules to move horizontally along a first horizontal direction and a second horizontal direction. This application ensures welding quality and fundamentally avoids the generation of lamination microcracks by eliminating cell warpage and precisely straightening the spatial posture of the solder strip before welding.

Description

Technical Field

[0001] This application relates to the field of photovoltaic module manufacturing equipment technology, and in particular to a welding apparatus for photovoltaic modules. Background Technology

[0002] In the welding process of photovoltaic modules, the solder strips from the previous cell string need to be welded to the solder strips from the next cell string, or both need to be welded simultaneously onto the busbar. The reliability of this process directly affects the performance of the photovoltaic module.

[0003] Currently, due to the potential edge warping of solar cells and the ease with which the solder strips can shift, arch, or even overlap, the solar cells and solder strips are often in a poor spatial state before welding. Therefore, during welding, problems such as incomplete welding and uneven welding stress are easily caused, which can induce microcracks in the solar cells during subsequent lamination processes, seriously affecting the long-term reliability and power output of photovoltaic modules. Summary of the Invention

[0004] Based on this, the present invention provides a welding device for photovoltaic modules to solve the problem that poor posture of the cells and welding strips during welding leads to poor welding quality and is prone to inducing microcracks in subsequent lamination processes, affecting the long-term reliability of the modules.

[0005] The present invention provides a welding apparatus for photovoltaic modules, comprising:

[0006] The pressing module includes two pressure plates arranged side by side along a first horizontal direction, and a lifting drive mechanism for driving the pressure plates to rise and fall. Each pressure plate has a relief groove at its bottom that can accommodate the solder strips on the battery string.

[0007] A strip straightening module, at least partially located above the pressure plate and connected to the lifting drive mechanism, includes:

[0008] Two alignment modules are arranged opposite each other along the first horizontal direction. Each alignment module has a plurality of alignment rods arranged along the second horizontal direction on the side facing the other alignment module. The second horizontal direction is perpendicular to the first horizontal direction. Within the same alignment module, the spacing between adjacent alignment rods is configured to accommodate the embedding of one alignment rod of the other alignment module. The ends of the alignment rods of the two alignment modules can be moved between the two pressure plates.

[0009] A drive module, connecting the two regularization modules, is configured to drive the regularization modules to move horizontally along the first horizontal direction and the second horizontal direction.

[0010] In one embodiment, the drive module includes:

[0011] A first driving mechanism is connected to the two regularization modules and is used to drive the two regularization modules to move toward or away from each other along the first horizontal direction.

[0012] The second drive mechanism is connected to the two straightening modules and the first drive mechanism, and is used to drive the two straightening modules to move along the second horizontal direction.

[0013] In one embodiment, the first driving mechanism includes a first guide member disposed on extending along the first horizontal direction, two first moving members movably disposed on the first guide member, and two first driving components that drive the two first moving members respectively.

[0014] The second driving mechanism includes two sets of linear motion units respectively fixed on the two first moving parts. Each set of linear motion units includes a second guide member arranged along the second horizontal direction, a second moving part movably arranged on the second guide member, and a second driving component for driving the second moving part.

[0015] The two regularization modules are respectively disposed on the two second moving parts.

[0016] In one embodiment, the welding device further includes a bracket connected to the output end of the lifting drive mechanism. The pressure plate and the welding strip straightening module are both mounted on the bracket so as to be driven synchronously by the lifting drive mechanism.

[0017] A buffer mechanism is connected between the pressure plate and the bracket to provide elastic cushioning after the pressure plate contacts the battery cell.

[0018] In one embodiment, in the initial state, the lower surface of the pressure plate is lower than the lower end of the straightening rod, and the preset height difference between the two is less than the buffer stroke of the buffer mechanism and greater than the protrusion height of the solder strip on the surface of the battery cell.

[0019] In one embodiment, the straightening module further includes a fixing plate that extends along the second horizontal direction and is fixedly connected to the second moving member, and each of the straightening rods is spaced apart on the fixing plate along the extension direction of the fixing plate;

[0020] The alignment rod includes a horizontal rod segment and a vertical rod segment. The horizontal rod segment is connected to the fixed plate and extends from the fixed plate toward another alignment module along the first horizontal direction. The vertical rod segment is fixedly connected to the end of the horizontal rod segment away from the fixed plate and extends vertically downward.

[0021] In one embodiment, the first guide member is provided with a limiting block, and when the two first moving members abut against the two sides of the limiting block, the vertical segments of each of the straightening rods of the two straightening modules are arranged in a straight line extending along the second horizontal direction; and / or,

[0022] In the same alignment module, the vertical segments of each alignment rod are arranged at equal intervals along the second horizontal direction, and the spacing between adjacent vertical segments matches the spacing between adjacent solder strips to be welded on the battery string.

[0023] In one embodiment, the welding apparatus further includes a support base plate located directly below the pressure plate for supporting the battery string.

[0024] In one embodiment, the support base plate has two strip-shaped grooves extending along the second horizontal direction, and the two strip-shaped grooves are respectively located directly below the two sets of regularized modules.

[0025] In one embodiment, the supporting base plate is a welding heating plate, and the heating surface of the welding heating plate is the upper surface of the portion between the two strip grooves.

[0026] Compared with the prior art, the present invention has at least the following technical effects:

[0027] The aforementioned welding device, through the parallel lower pressure plate and the clearance groove at its bottom, flattens the edge of the battery cell and eliminates the slope, while accommodating and guiding the welding strip, thus preventing damage to the welding strip and establishing an initial state for its straight extension.

[0028] By using bidirectional horizontally movable alignment rods on two alignment modules, the superimposed solder strips can be actively separated physically, and lateral misalignment of the solder strips can be corrected. This fundamentally solves the problems of solder strip stacking and misalignment, greatly reducing the risk of microcracks in the laminated cells due to solder strip overlap or misalignment. Furthermore, the interlocking spacing design of the two alignment rods allows them to interlock and converge, smoothly and evenly pressing the ends of the solder strips onto the surface of the busbar during downward pressure. This ensures a tight fit between the solder strips and the busbar, creating ideal interface conditions for subsequent hot-press welding processes and achieving high-quality pre-welding alignment. Attached Figure Description

[0029] Figure 1 A schematic diagram of a battery cell with warped edges and overlapping solder strips;

[0030] Figure 2 This is a schematic diagram of the welding device in one embodiment;

[0031] Figure 3 This is a front view of the welding apparatus in one embodiment;

[0032] Figure 4 This is a schematic diagram of the welding device from another angle in one embodiment;

[0033] Figure 5 This is a schematic diagram of a battery string placed in a welding device in one embodiment;

[0034] Figure 6 This is a schematic diagram of the welding device separating and stacking welding strips in one embodiment;

[0035] Figure 7 The diagram shows two sets of alignment rods changing from a separated state to an interlaced and joined state in one embodiment. In the diagram, (a) shows the two sets of alignment rods misaligned along the second horizontal direction, (b) shows the two sets of alignment rods interlaced, and (c) shows the two sets of alignment rods joined together.

[0036] The reference numerals in the accompanying drawings include:

[0037] 1-Battery string; 2-Soldering strip; 3-Busbar;

[0038] 100 - Pressing module; 110 - Lifting drive mechanism; 120 - Pressure plate; 121 - Clearance groove;

[0039] 200-Strip straightening module; 210-Straightening module; 211-Straightening rod; 2111-Horizontal rod segment; 2112-Vertical rod segment; 212-Fixing plate; 220-Drive module; 221-First drive mechanism; 2211-First guide; 2212-First moving component; 2213-First drive component; 222-Second drive mechanism; 2221-Second guide; 2222-Second moving component; 2223-Second drive component;

[0040] 300 - Support frame; 310 - Top plate; 320 - Side plate;

[0041] 400 - Buffer mechanism; 410 - Connecting plate; 420 - Spring;

[0042] 500 - Limit stop;

[0043] 600 - Support base plate; 610 - Strip groove; 620 - Heating surface. Detailed Implementation

[0044] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments.

[0045] In the production process of photovoltaic modules, the solder strips between the cell strings need to be simultaneously welded onto the busbar to achieve current convergence.

[0046] However, currently, solar cells and solder ribbons are often in poor spatial condition before welding. For example, solar cells are prone to edge warping, and solder ribbons are prone to misalignment, arching, or even overlapping. This can easily lead to problems such as incomplete welding and uneven welding stress during welding, and can induce microcracks in solar cells during subsequent lamination processes, seriously affecting the long-term reliability and power output of photovoltaic modules.

[0047] For example, see Figure 1 In the example shown, the edges of both battery strings 1 in the figure show obvious warping, and the solder strips 2 extending from the battery strings 1 are in an irregular state of overlapping.

[0048] To address the aforementioned problems, this invention provides a welding apparatus for photovoltaic modules. By eliminating cell warpage and precisely regulating the spatial state of the solder strip 2 before welding, welding quality is ensured, fundamentally preventing the generation of lamination microcracks.

[0049] Specifically, such as Figures 2 to 7 As shown, the welding apparatus for photovoltaic modules provided in this embodiment of the invention includes a pressing module 100 and a ribbon straightening module 200.

[0050] The pressing module 100 includes two pressure plates 120 arranged side by side along the first horizontal direction, and a lifting drive mechanism 110 for driving the pressure plates 120 to rise and fall. Each pressure plate 120 has a relief groove 121 at its bottom that can accommodate the welding strip 2 on the battery string 1.

[0051] The strip straightening module 200 is located at least partially above the pressure plate 120 and is connected to the lifting drive mechanism 110. It includes two straightening modules 210 and a drive module 220 connecting the two straightening modules 210.

[0052] Two straightening modules 210 are arranged opposite each other along a first horizontal direction, and each straightening module 210 has a plurality of straightening rods 211 arranged along a second horizontal direction on the side facing the other straightening module 210. The second horizontal direction is perpendicular to the first horizontal direction. In the same straightening module 210, the spacing between adjacent straightening rods 211 is configured to accommodate the insertion of a straightening rod 211 of the other straightening module 210. The ends of the straightening rods 211 of the two straightening modules 210 can be moved between the two pressure plates 120.

[0053] The drive module 220, which connects to two straightening modules 210, is configured to drive the straightening modules 210 to move horizontally along a first horizontal direction and a second horizontal direction.

[0054] Wherein, the first horizontal direction is the long side direction of battery string 1, such as... Figure 2 The left and right directions are shown; the second horizontal direction is the direction of the shorter side of battery string 1, as shown. Figure 2 The front and back directions of the indicated location.

[0055] The welding apparatus according to the above embodiment can be divided into three main stages in its operation:

[0056] Phase 1: Flattening the solar cells.

[0057] The lifting drive mechanism 110 is activated, driving the two pressure plates 120 to move downwards synchronously. The pressure plates 120 effectively flatten the warped areas at the edges of the battery cells by applying controllable mechanical pressure, restoring them to a flat state. During this process, the welding strip 2 extending from the battery cell is naturally guided and accommodated in the clearance groove 121 at the bottom of the pressure plate 120, preventing the welding strip 2 from being directly squeezed and damaged when the pressure plate 120 is pressed down. Moreover, the clearance groove 121 plays an effective guiding and lateral restraining role for the welding strip 2, ensuring that the welding strip 2 maintains a stable straight extension posture during the process of flattening the battery cell, thereby directly eliminating the phenomenon of the welding strip 2 "climbing" or arching caused by the warping of the battery cell.

[0058] Second stage: Separation of the superimposed solder strips.

[0059] First, the drive module 220 controls the two alignment modules 210 to move along the second horizontal direction, causing the two sets of alignment rods 211 to form an alternating layout on the horizontal plane. That is, along the second horizontal direction, one set of alignment rods 211 is roughly located on one side of the left solder strip array, and the other set is located on the other side of the right solder strip array (e.g., ...). Figure 6 (The state shown).

[0060] Since the welding strip straightening module 200 is at least partially located above the pressure plate 120 and connected to the lifting drive mechanism 110, when the lifting drive mechanism 110 drives the pressure plate 120 to move downward, the two straightening modules 210 will also descend to the preset working height, so that the lower end of each straightening rod 211 achieves a suitable working relationship with the corresponding welding strip 2 in the vertical direction (for example, the lower end of the straightening rod 211 is at least lower than the upper surface of the welding strip 2), ensuring that each welding strip 2 is adjacent to a corresponding straightening rod 211 on its side.

[0061] Then, the drive module 220 drives the two sets of alignment rods 211 to move relative to each other along the second horizontal direction, such as... Figure 6 The direction of movement is shown. This action causes the two sets of alignment rods 211 to act on the paired welding strips 2 from both sides, causing them to produce relative displacement. This operation can effectively separate the welding strips 2, which may originally be stacked together, laterally, so that they are spread out in the second horizontal direction to form a neat single plane arrangement, thereby eliminating the risk of uneven height and stress concentration caused by the stacking of welding strips 2.

[0062] Phase 3: Positioning of solder strip 2.

[0063] After the separation of the superimposed solder strips is completed, the lifting drive mechanism 110 drives the straightening module 210 to rise, and the straightening rod 211 disengages from the solder strip 2. Then, the drive module 220 manipulates the straightening module 210 to reposition itself spatially: as... Figure 7 As shown in diagram a, the two sets of regular rods 211 are first staggered by a certain distance in the second horizontal direction. For example... Figure 7 As shown in b, the two regularization modules 210 are then driven to move towards each other along the first horizontal direction, achieving complete interlacing of the two sets of regularization rods 211 in three-dimensional space (i.e., one set of regularization rods 211 is embedded in the gap of the other set of regularization rods 211). Figure 7 As shown in c, the drive module 220 then drives the straightening module 210 to move towards each other along the second horizontal direction, so that the two sets of straightening rods 211 that have been intersected come closer to each other and merge, and finally align to form a closely arranged array of straightening rods 211, and then move to the position directly above all the welding strips 2.

[0064] Finally, the lifting drive mechanism 110 controls the entire sizing module 210 to descend again. At this time, the sizing rods 211, which have been joined together, smoothly and evenly press the ends of the corresponding two welding strips 2 onto the surface of the lower busbar 3, so that the welding strips 2 and the busbar 3 are closely attached, creating ideal interface conditions for the subsequent hot pressing welding process.

[0065] The above embodiments ensure that each welding strip 2 is straight, single-layered, and accurately positioned before welding, thus guaranteeing the strength and uniformity of the welding interface and avoiding lamination cracks. This directly improves the mechanical reliability and electrical performance of photovoltaic modules during long-term operation, and comprehensively enhances product yield and the stability of long-term power output.

[0066] See Figure 2 In this embodiment, the welding device is also provided with a bracket 300. The bracket 300 is connected to the output end of the lifting drive mechanism 110, and the pressure plate 120 in the pressing module 100 and the welding strip straightening module 200 are both installed on this bracket 300, so that the pressing module 100 and the welding strip straightening module 200 are integrated into a whole that can be driven and lifted by the same lifting drive mechanism 110, realizing structural integration and compact design.

[0067] Specifically, in combination Figure 2 As shown, the bracket 300 may include a top plate 310 and two side plates 320. The top plate 310 is horizontally arranged, and its upper part is fixedly connected to the output end of the lifting drive mechanism 110, so that the lifting drive mechanism 110 can drive the entire bracket 300 and the integrated modules on it to lift synchronously.

[0068] The lifting drive mechanism 110 in this embodiment can be a conventional linear drive component, such as a ball screw pair, a combination of synchronous belt and servo motor, or a pneumatic / hydraulic cylinder. Figure 2 In the example, the lifting drive mechanism 110 specifically uses the first cylinder as the power source.

[0069] See also Figure 2 Two side panels 320 are fixed to the lower sides of the top plate 310, and both side panels 320 are L-shaped plates with vertical and horizontal extensions. See also... Figure 3 The vertical extensions of the two side plates 320 are connected to the top plate 310, and the horizontal extensions extend inward from the lower end of the vertical extensions (i.e. towards the other side plate 320). The ends of the horizontal extensions of the two side plates 320 face each other.

[0070] Corresponding to the above structural design, two pressure plates 120 are respectively installed at the ends of the horizontal extensions of the two side plates 320, with their long sides extending along the second horizontal direction. The two pressure plates 120 are kept flush in the vertical direction to ensure that the downward pressure is applied evenly to the edges of the battery strings 1 on both sides. At the same time, since the ends of the horizontal extensions of the two side plates 320 are close to each other, the horizontal distance between the two pressure plates 120 is reduced, for example, to be basically consistent with the gap between two adjacent battery strings 1 to be processed, thereby achieving precise alignment of the two pressure plates 120 with the edges of their respective target battery cells.

[0071] Meanwhile, in the above structural design, a relatively wide space is formed between the vertical extensions of the two side plates 320, which provides ample space for the installation of the welding strip straightening module 200, which is conducive to achieving compact integration of the overall structure.

[0072] In some embodiments, to protect the solar cells from mechanical damage during the flattening process, a buffer mechanism 400 is also connected between each pressure plate 120 and the support 300 that drives its movement, so as to provide elastic buffering after the pressure plate 120 contacts the solar cell.

[0073] Specifically, such as Figure 2 , Figure 3 and Figure 4 As shown, the buffer mechanism 400 may include a connecting plate 410 and multiple springs 420. The connecting plate 410 is fixedly connected to the end of the horizontally extending portion of the side plate 320 and extends horizontally along a second horizontal direction. The multiple springs 420 are evenly spaced and vertically mounted on the lower side of the connecting plate 410. The pressure plate 120 is fixedly connected to the lower ends of all the springs 420 and also extends horizontally along the second horizontal direction.

[0074] Based on the above structural design, during the process of the lifting drive mechanism 110 driving the pressure plate 120 to descend as a whole via the bracket 300, after the bottom surface of the pressure plate 120 contacts the surface of the battery cell, if the lifting drive mechanism 110 continues to drive downward, the spring 420 can be compressed, thereby converting the rigid downward pressure into an adjustable elastic pressure transmitted through the spring 420. This elastic buffering mechanism can effectively prevent the brittle battery cell from cracking or being damaged due to excessive pressure or excessive downward pressure, significantly improving the safety of the operation process while ensuring the flattening effect.

[0075] In this embodiment, the clearance groove 121 at the bottom of the pressure plate 120 is used to collect the protruding solder strip 2 on the surface of the battery cell when the pressure plate 120 is pressed down, so as to avoid the lower surface of the pressure plate 120 directly squeezing the solder strip 2 and thus avoid damage to the solder strip 2.

[0076] For details, see Figure 2 In this embodiment, each pressure plate 120 has multiple clearance grooves 121 at its bottom, the number of which matches the number of solder strips 2 on the corresponding battery string 1, specifically, it can be set to be equal to or greater than the number of solder strips 2. Furthermore, these clearance grooves 121 are arranged at equal intervals along the second horizontal direction (i.e., the array direction of the solder strips 2), and the interval distance is equal to the spacing between adjacent solder strips 2 on the battery cell.

[0077] Furthermore, each clearance groove 121 is a through groove extending along a first horizontal direction (i.e., the length direction of the weld strip 2), and its cross-sectional dimensions match the physical dimensions of the weld strip 2. For example, the width of the groove can be set to be equal to or slightly larger than the width of the weld strip 2, and the depth of the groove can be set to be equal to or slightly larger than the thickness of the weld strip 2. This allows the clearance groove 121 to effectively limit the space and guide the path of the weld strip 2 during the flattening process, preventing the weld strip 2 from shifting, bending, or arching under pressure.

[0078] Based on the structural design of the aforementioned relief groove 121, each welding strip 2 can be individually accommodated in a corresponding relief groove 121, thereby achieving synchronous guidance and reliable isolation of all welding strips 2 and avoiding mutual interference or pressure displacement between welding strips 2.

[0079] like Figure 5 As shown, in this embodiment, the positions of the two pressure plates 120 are set to face the edge areas of the battery strings 1 on both sides respectively. The solder strips 2 extending from the battery cells on both sides are naturally located in the gap between the two pressure plates 120.

[0080] Based on the above layout, along the first horizontal direction, the alignment rods 211 of the two alignment modules 210 in this embodiment are also arranged in the same gap area between the two pressure plates 120. This allows the alignment rods 211 to act directly and unobstructed on all the weld strips 2 located in the gap, thereby performing alignment actions such as separation and alignment.

[0081] For example, combining Figure 3 and Figure 5 As shown, in this embodiment, the drive module 220 of the ribbon straightening module 200 is arranged in the space between the vertical extension portions of the two side plates 320, directly above the two pressure plates 120. This layout ensures that the straightening module 210 and straightening rod 211 installed on the drive module 220 can naturally extend downward and be located within the gap area.

[0082] Specifically, see Figure 2 and Figure 3 The drive module 220 includes a first drive mechanism 221 and a second drive mechanism 222.

[0083] The first drive mechanism 221 is connected to two straightening modules 210 and is used to drive the two straightening modules 210 to move in opposite or opposite directions along the first horizontal direction (the length direction of the battery string 1), providing a basis for the insertion and separation of the two sets of straightening rods 211.

[0084] For example, in some embodiments, the first drive mechanism 221 can be driven synchronously by a single drive source in conjunction with a bidirectional motion mechanism. Specifically, a servo motor can be used to drive a bidirectional lead screw, with two alignment modules 210 connected to oppositely threaded sections of the lead screw. When the servo motor operates, the two alignment modules 210 can be moved synchronously and at equal speeds towards or away from each other via the lead screw and nut pair.

[0085] In other embodiments, the first drive mechanism 221 may also employ two independent linear drive components to drive the two regularization modules 210 respectively. Each drive component may be a conventional linear motion unit, such as an electric cylinder consisting of a ball screw pair and a servo motor, a combination of a synchronous belt and a servo motor, a pneumatic / hydraulic cylinder, etc.

[0086] exist Figure 3In the specific example shown, the first drive mechanism 221 includes a first guide member 2211 extending along a first horizontal direction, two first moving members 2212 movably disposed on the first guide member 2211, and two first drive components 2213 that drive the two first moving members 2212 respectively. The first guide member 2211 can be a first slide rail, which is directly mounted on the lower side of the top plate 310; the first moving members 2212 can be first sliders, which are slidably mounted on the first slide rail. The two alignment modules 210 are connected to these two first sliders via the second drive mechanism 222. The first drive component 2213 can be a second cylinder, with its cylinder body fixed to the first slide rail or bracket 300, and the end of its piston rod connected to the corresponding first slider. With this configuration, by controlling the actions of the two second cylinders respectively, the two alignment modules 210 can be independently driven to move along the first horizontal direction, achieving flexible position control and speed adjustment.

[0087] In this embodiment, the second drive mechanism 222 is connected to the two straightening modules 210 and the first drive mechanism 221, and is used to drive the two straightening modules 210 to move linearly along the second horizontal direction (the direction of the short side of the battery string 1), providing a basis for the two sets of straightening rods 211 to come together and separate the welding strips 2.

[0088] For example, see Figure 3 and Figure 4 The second drive mechanism 222 may include two independent linear motion units, which are respectively fixedly mounted on two first moving parts 2212 (first sliders) of the first drive mechanism 221, so as to move as a whole as the first moving parts 2212 move in the first horizontal direction. Each linear motion unit may also be implemented using conventional linear motion components in the art.

[0089] exist Figure 4 In a specific example shown, each linear motion unit of the second drive mechanism 222 includes: a second guide member 2221 arranged along the second horizontal direction, a second moving member 2222 movably arranged on the second guide member 2221, and a second drive component 2223 driving the second moving member 2222. Similarly, the second guide member 2221 can be a second slide rail, which is fixedly mounted on the first slider; the second moving member 2222 can be a second slider, which is slidably mounted on the second slide rail; the second drive component 2223 can be a third cylinder, whose cylinder body can be fixed to the second slide rail itself or a nearby support structure 300, and whose piston rod end is connected to the second slider. The two alignment modules 210 are respectively mounted on the two second moving members 2222 (second sliders). With this configuration, by controlling the extension and retraction of the two third cylinders respectively, the two alignment modules 210 can be independently driven to move along the second horizontal direction, thereby achieving flexible position and speed control.

[0090] Combining the aforementioned first drive mechanism 221 and second drive mechanism 222, independent driving of the two straightening modules 210 in two orthogonal directions (i.e., the first horizontal direction and the second horizontal direction) in the horizontal plane is realized, which is the basis for the straightening rod 211 to perform operations such as interlacing to separate the welding strip 2 and aligning to straighten the position of the welding strip 2.

[0091] See Figure 3 In this embodiment, the positional relationship between the modules also satisfies the following adjustment: In the initial (i.e., naturally inactive) state of the device, the initial height of the lower surface of the pressure plate 120 is lower than the lower end of the alignment rod 211, and there is a preset height difference between the two, which is less than the buffer stroke of the buffer mechanism 400 and greater than the protrusion height of the welding strip 2 on the surface of the battery cell.

[0092] The buffer stroke refers to the distance the spring is compressed from its natural state to its fully compressed state; that is, the maximum displacement or maximum compression that the buffer mechanism can absorb. With this setting, the preset height difference is less than the buffer stroke, ensuring that when the pressure plate 120 presses the battery cell and the bracket 300 continues to descend, the alignment rod 211 can reach at least the working height required for interaction with the welding strip 2 within the compression stroke range of the spring 420, preventing the alignment rod 211 from not reaching the height of the welding strip 2 after the spring 420 is fully compressed. Conversely, the preset height difference is greater than the protrusion height of the welding strip 2 on the battery cell surface, ensuring that the lower end of the alignment rod 211 will not prematurely contact the welding strip 2 before the pressure plate 120 has completed the flattening operation. This achieves the separation and coordinated operation of the flattening and alignment actions.

[0093] Based on the above structural design, its collaborative working process is as follows:

[0094] The pressure plate 120 flattens the solar cells: The lifting drive mechanism 110 is activated, driving the entire bracket 300 (along with the pressure plate 120 and the welding strip straightening module 200 on it) to move downwards. The pressure plate 120 first contacts and begins to flatten the warped edges of the solar cells.

[0095] Buffer Intervention and Lowering of Alignment Rod 211: After the pressure plate 120 has pressed the battery cells, the lifting drive mechanism 110 continues to drive the entire support 300 downwards. At this time, due to the reaction force of the battery cells, the pressure plate 120 cannot continue to move downwards, and the downward force of the support 300 is converted into compression of the buffer spring 420 connected to it. During this process, the alignment rod 211 installed on the support 300, driven by the support 300, overcomes the aforementioned height difference and continues to move downwards until its lower end reaches the preset alignment working position (e.g., intervening between the layers of the welding strip 2 or contacting the upper surface of the welding strip 2). In this process, the buffering effect of the spring 420 effectively prevents the battery cells from being damaged due to overtravel.

[0096] The alignment rod 211 returns to its original position: After the alignment operation is completed, the lifting drive mechanism 110 drives the support 300 to rise. Because the elastic restoring force of the buffer spring 420 continuously acts on the pressure plate 120, it maintains a stable pressing state on the edge of the battery cell throughout the entire process of the alignment rod 211 rising and disengaging from the welding strip 2. This ensures that the lifting action of the alignment rod 211 and the flattening operation of the pressure plate 120 on the battery cell are independent and do not interfere with each other, achieving functional decoupling and synergy.

[0097] Through the above integrated design, the flattening of the battery cells and the lifting drive of the leveling rod 211 are realized simultaneously with only one lifting drive mechanism 110, without the need for additional lifting mechanisms. This significantly simplifies the mechanical structure and control system, and improves the reliability and economy of the device.

[0098] like Figure 2 and Figure 4 As shown, each alignment module 210 includes a fixed plate 212, and the fixed plates 212 of the two alignment modules 210 are respectively fixedly installed on the lower side of the two second moving parts 2222 (second sliders). Furthermore, the fixed plate 212 extends along a second horizontal direction, and all alignment rods 211 of the same alignment module 210 are arranged at equal intervals along the second horizontal direction on the side of the fixed plate 212 facing the other fixed plate 212, forming an alignment rod array. This arrangement, by using the fixed plate 212 as a mounting support for each alignment rod 211, integrates multiple alignment rods 211 into a modular motion unit, ensuring the high consistency of the movement of all alignment rods 211.

[0099] In this embodiment, the number of aligning rods 211 provided on each fixing plate 212 is matched with the number of solder strips 2 extending from the edge of the corresponding battery string 1, and is usually set to be equal to or slightly more than the number of solder strips 2. This arrangement ensures that each extended solder strip 2 can be aligned by an aligning rod 211, so as to ensure that each solder strip 2 can be effectively utilized.

[0100] Please continue reading Figure 2In this embodiment, all the alignment rods 211 are specifically designed as "L-shaped" rods, which include mutually perpendicular horizontal rod segments 2111 and vertical rod segments 2112. The horizontal rod segments 2111 are connected to the fixing plate 212 and extend from the fixing plate 212 toward another alignment module 210 along a first horizontal direction. The vertical rod segments 2112 are fixedly connected to the end of the horizontal rod segments 2111 away from the fixing plate 212 and extend vertically downward.

[0101] Specifically, the horizontal bar segment 2111 extends along the first horizontal direction, with one end fixedly connected to the side of the fixed plate 212 and the other end being free. The main function of this bar segment is to allow the main body of the aligning bar 211 (i.e., the vertical bar segment 2112) to extend out from the side of the fixed plate 212, thereby forming a defined horizontal distance between the vertical bar segment 2112 and the side of the fixed plate 212. This distance ensures that the aligning bars 211 of the two sets of aligning modules 210 can interweave with each other in the first horizontal direction without structural interference.

[0102] The upper end of the vertical segment 2112 is connected to the free end of the horizontal segment 2111 and extends downward in the vertical direction. The vertical segment 2112 is the direct execution part of the regularization function: when it descends and intervenes in the array of welding strips 2, it can be used to separate the vertically stacked welding strips 2 from the side; in its final pressing stage, it is used to press the welding strips 2 downward, making them flat, adhere and press tightly against the surface of the busbar 3, preparing for welding.

[0103] Furthermore, in this embodiment, the spacing between adjacent alignment rods 211 is approximately equal to the spacing between adjacent welding strips 2 extending from the edge of the battery string 1.

[0104] Specifically, in the same alignment module 210, the vertical rod segments 2112 of each alignment rod 211 are arranged at equal intervals along the second horizontal direction, and the spacing between adjacent vertical rod segments 2112 matches the spacing between adjacent welding strips 2 to be welded on the battery string 1.

[0105] This configuration ensures that during the final straightening and pressing stage, each straightening rod 211 can be precisely aligned and act on a corresponding welding strip 2, thereby achieving precise pressing and positioning. Furthermore, the spacing naturally creates an insertion gap between adjacent straightening rods 211, accommodating the insertion of straightening rods 211 from another straightening module 210, thus providing a basis for the complete staggered interlocking of the two sets of straightening rods 211 on the horizontal plane.

[0106] In some embodiments, in order to ensure that the two sets of alignment rods 211 can be precisely aligned after interlacing and closing to form a straight line arrangement extending along the second horizontal direction, the device is also provided with a positioning mechanism.

[0107] For example, the first guide member 2211 is provided with a limiting block 500. When the two first moving members 2212 abut against the two sides of the limiting block 500, the vertical rod segments 2112 of each straightening rod 211 of the two straightening modules 210 are arranged in a straight line extending along the second horizontal direction.

[0108] Specifically, such as Figure 2 and Figure 3 As shown, in conjunction with the aforementioned structural design of the first driving mechanism 221, the limiting block 500 is fixedly installed at the central position of the first guide member 2211. Furthermore, its width satisfies the following condition: when the two first sliders are driven by the first driving component 2213 to move towards each other and finally abut against the two sides of the limiting block 500, the two regularized modules 210 exactly reach the preset final merging position. Figure 7 b、 Figure 7 (Position shown in c). In this position, the two sets of regular rods 211 have interlocked, and the vertical segments 2112 of all regular rods 211 are strictly aligned in the second horizontal direction, forming a straight arrangement.

[0109] By setting this limit stop 500, a mechanical stop is provided for the movement of the first drive mechanism 221, which simplifies the control logic, eliminates the need to rely on sensor feedback for precise positioning, and ensures the consistency of the closing position of the two sets of straightening rods 211 in each operation. This ensures the repeatability and stability of the straightening and positioning of the welding strip 2, making the entire straightening process more reliable.

[0110] Further, see Figure 2 The welding apparatus in this embodiment also includes a support base plate 600. This support base plate 600 is located directly below the two pressure plates 120, and its function is to provide a stable, flat, and rigid support surface for the battery string 1 placed on it. Figure 5 As shown, when the lifting drive mechanism 110 drives the pressure plate 120 to press down, the edge of the battery string 1 can be pressed between the bottom surface of the pressure plate 120 and the top surface of the support base plate 600. The flat surface of the support base plate 600 ensures that the edge of the battery cell can be uniformly squeezed, thereby effectively and reliably eliminating its warping deformation.

[0111] Furthermore, see Figure 2 and Figure 5The support base plate 600 is also provided with two strip-shaped grooves 610 extending along the second horizontal direction. These two strip-shaped grooves 610 are located directly below the two sets of straightening modules 210. The strip-shaped grooves 610 are mainly used to provide greater downward space for the vertical movement of the straightening rods 211. Specifically, when operations such as separating the superimposed welding strips 2 are required, the two sets of straightening rods 211 can be completely inserted into the corresponding strip-shaped grooves 610. Based on this, relative displacement along the second horizontal direction is then performed. Since the strip-shaped grooves 610 provide sufficient depth, it can effectively prevent the lower end of the straightening rod 211 from contacting the surface of the support base plate 600, thereby completely eliminating the risk of structural interference during the movement and ensuring the smooth execution of the straightening action.

[0112] Furthermore, in this embodiment, the supporting base plate 600 can directly utilize the existing welding heating plate of the welding system. This welding heating plate typically has a flat supporting surface and heating function. This integration method achieves functional reuse and structural simplification. During the preparation stage, the welding heating plate, as the supporting base plate 600, provides a flat and rigid support for the battery string 1, assisting in flattening the battery cells and preparing the welding strip 2. In the subsequent welding stage, without transferring the battery string 1, the heating function of the heating plate can be directly activated to perform hot-press welding on the welding strip 2 that has been prepared and pressed onto the busbar 3.

[0113] For more details, see Figure 2 When a welding heating plate is used as the support base plate 600 of this device, its heating surface 620 is the upper surface portion located between the two strip grooves 610, corresponding to the pressing area of ​​the welding strip 2 and the busbar 3. This design enables selective local heating, while other areas of the base plate that only serve a supporting function (such as the area supporting the battery cells) are not heated, thus avoiding unnecessary heating of the main body of the battery cells.

[0114] The welding apparatus for photovoltaic modules provided in the above embodiments includes the following steps in its usage:

[0115] S1: Initial setup and battery string 1 positioning

[0116] like Figure 5 As shown, the battery string 1 is placed on the support base plate 600, with the edges of the battery string 1 overlapping the surface of the support base plate 600. The welding strip 2 extends naturally and is initially aligned with the busbar 3 on the heating surface 620 of the support base plate 600. At this time, the lifting drive mechanism 110 is in the initial high position, and the bottom position of the pressure plate 120 is lower than the leveling rod 211.

[0117] S2: Press down to flatten the edge of the battery cell and straighten the solder strip 2.

[0118] The lifting drive mechanism 110 drives the top plate 310 to move downward as a whole. The support 300 and spring 420 buffer the movement, causing the pressure plate 120 to press down on the edge of the battery string 1. During the pressing process, the spring 420 absorbs the pressure to prevent damage to the battery cells. The pressure plate 120 presses down to the surface of the battery cells, and the clearance groove 121 at the bottom of the pressure plate 120 aligns with the welding strip 2 to ensure that the welding strip 2 has room to extend forward.

[0119] S3: The guide rod 211 descends and separates from the weld strip 2.

[0120] The lifting drive mechanism 110 drives the top plate 310 to continue moving downwards until the aligning rods 211 reach the slot. Then, each aligning module 210 operates independently: the third cylinder drives the second slider to move along the second slide rail. This causes the two aligning rods 211 to move relative to each other along the short side of the battery string 1 (one forward and one backward), as shown below. Figure 6 As shown. The two sets of regular rods 211 move relative to each other, separating and superimposing the welding strip 2.

[0121] S4: Displacement and linear arrangement of regular rod 211

[0122] The lifting drive mechanism 110 moves the entire assembly upward, raising the height of the alignment rod 211 above the position of the welding strip 2. Then, each alignment module 210 operates independently: the second cylinder drives the first slider to move along the first slide rail. This causes the two alignment rods 211 to move relative to each other along the long side of the battery string 1 until the two first sliders contact the limit stop 500. At this point, the vertical rod segments 2112 of the two alignment rods 211 are arranged in a straight line extending along the second horizontal direction, as shown below. Figure 7 As shown in b.

[0123] S5: Preparation for merging the 211-aligned rod with the 2-welded strip for pressing.

[0124] The third cylinder restarts, pushing the two sets of leveling rods 211 to move relative to each other along the short side, causing every two leveling rods 211 to contact and merge into one, as shown below. Figure 7 As shown in c. After merging, the drive alignment rod 211 moves to directly above the corresponding two welding strips 2.

[0125] S6: Overall pressing and welding execution

[0126] The lifting drive mechanism 110 moves the entire unit downwards, while the pressure plate 120 maintains its pressure on the battery edge. Simultaneously, the combined alignment rod 211 continues to press down, pressing the welding strip 2 onto the surface of the busbar 3 to form a stable welding contact surface. Then, the heating surface 620 starts heating, completing the pressing and welding of the welding strip 2 and the busbar 3. After welding, all cylinders reset, and the device rises back to its original position.

[0127] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0128] The structures, proportions, sizes, etc., illustrated in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the conditions under which the present invention can be implemented. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and objectives that the present invention can produce, should still fall within the scope of the technical content disclosed in the present invention.

[0129] The orientations or positional relationships indicated by terms such as "upper," "lower," "left," "right," "middle," "longitudinal," "lateral," "horizontal," "inner," "outer," "radial," and "circumferential" used in this specification are based on the orientations or positional relationships shown in the accompanying drawings and are only for the purpose of simplifying the description. They do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the present invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

Claims

1. A welding apparatus for photovoltaic modules, characterized in that, include: The pressing module (100) includes two pressure plates (120) arranged side by side along the first horizontal direction, and a lifting drive mechanism (110) for driving the pressure plates (120) to rise and fall. Each pressure plate (120) has a relief groove (121) at its bottom that can accommodate the solder strip (2) on the battery string (1). A strip straightening module (200), at least partially located above the pressure plate (120) and connected to the lifting drive mechanism (110), comprises: Two alignment modules (210) are arranged opposite each other along the first horizontal direction. Each alignment module (210) has a plurality of alignment rods (211) arranged along the second horizontal direction on the side facing the other alignment module (210). The second horizontal direction is perpendicular to the first horizontal direction. In the same alignment module (210), the spacing between adjacent alignment rods (211) is configured to accommodate the alignment rods (211) of the other alignment module (210) to be embedded. The ends of the alignment rods (211) of the two alignment modules (210) can be moved between the two pressure plates (120). A drive module (220), connected to two regularization modules (210), is configured to drive the regularization modules (210) to move horizontally along the first horizontal direction and the second horizontal direction.

2. The welding apparatus according to claim 1, characterized in that, The drive module (220) includes: The first driving mechanism (221) is connected to the two regularization modules (210) and is used to drive the two regularization modules (210) to move towards each other or away from each other along the first horizontal direction; The second drive mechanism (222) is connected to the two regularization modules (210) and the first drive mechanism (221) and is used to drive the two regularization modules (210) to move along the second horizontal direction.

3. The welding apparatus according to claim 2, characterized in that, The first drive mechanism (221) includes a first guide member (2211) disposed on a first guide member (2211) extending along the first horizontal direction, two first moving members (2212) movably disposed on the first guide member (2211), and two first drive components (2213) that drive the two first moving members (2212) respectively. The second drive mechanism (222) includes two sets of linear motion units respectively fixed on the two first moving parts (2212). Each set of linear motion units includes a second guide (2221) arranged along the second horizontal direction, a second moving part (2222) movably arranged on the second guide (2221), and a second drive component (2223) driving the second moving part (2222). The two regularization modules (210) are respectively disposed on the two second moving parts (2222).

4. The welding apparatus according to claim 3, characterized in that, It also includes a bracket (300), which is connected to the output end of the lifting drive mechanism (110). The pressure plate (120) and the welding strip straightening module (200) are both mounted on the bracket (300) so that they can be driven to lift synchronously by the lifting drive mechanism (110). A buffer mechanism (400) is connected between the pressure plate (120) and the bracket (300).

5. The welding apparatus according to claim 4, characterized in that, In the initial state, the lower surface of the pressure plate (120) is lower than the lower end of the straightening rod (211), and the preset height difference between the two is less than the buffer stroke of the buffer mechanism (400) and greater than the protrusion height of the solder strip (2) on the surface of the battery cell.

6. The welding apparatus according to claim 3, characterized in that, The straightening module (210) further includes a fixing plate (212), which extends along the second horizontal direction and is fixedly connected to the second moving member (2222). Each straightening rod (211) is spaced apart on the fixing plate (212) along the extension direction of the fixing plate (212). The straightening rod (211) includes a horizontal rod segment (2111) and a vertical rod segment (2112). The horizontal rod segment (2111) is connected to the fixed plate (212) and extends from the fixed plate (212) toward the other straightening module (210) along the first horizontal direction. The vertical rod segment (2112) is fixedly connected to the end of the horizontal rod segment (2111) away from the fixed plate (212) and extends vertically downward.

7. The welding apparatus according to claim 6, characterized in that, The first guide member (2211) is provided with a limiting block (500). When the two first moving members (2212) abut against the two sides of the limiting block (500), the vertical rod segments (2112) of each of the two straightening rods (211) of the two straightening modules (210) are arranged in a straight line extending along the second horizontal direction; and / or, In the same alignment module (210), the vertical rod segments (2112) of each alignment rod (211) are arranged at equal intervals along the second horizontal direction, and the spacing between adjacent vertical rod segments (2112) matches the spacing between adjacent welding strips (2) to be welded on the battery string (1).

8. The welding apparatus according to claim 1, characterized in that, It also includes a support base plate (600), which is located directly below the pressure plate (120) and is used to support the battery string (1).

9. The welding apparatus according to claim 8, characterized in that, The support base plate (600) has two strip-shaped grooves (610) extending along the second horizontal direction, and the two strip-shaped grooves (610) are respectively located directly below the two sets of regularization modules (210).

10. The welding apparatus according to claim 9, characterized in that, The supporting base plate (600) is a welding heating plate, and the heating surface (620) of the welding heating plate is the upper surface of the portion between the two strip grooves (610).

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