An automatic edging device for a photovoltaic module laminate

Abstract

The application relates to the technical field of photovoltaic module cutting equipment, and discloses an automatic trimming device for a photovoltaic module laminated piece, which comprises a base, a fixing frame fixedly installed on the base, a control element installed on the fixing frame, a first moving assembly arranged on the fixing frame, a second moving assembly fixedly installed at the moving end of the first moving assembly, a motor fixedly installed at the moving end of the second moving assembly, a disc-shaped cutter coaxially and fixedly connected to the output end of the motor, a third moving assembly arranged on the base, a bottom plate fixedly installed at the moving end of the third moving assembly, and a vacuum chuck clamp fixedly installed on the upper surface of the bottom plate. The first moving assembly is used for driving the disc-shaped cutter to vertically ascend and descend along the Z axis. Through trimming dynamic pose control, workpiece deviation caused by cutting force can be detected and self-adaptively adjusted in real time, and the core pain point proposed in the background art is solved.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic module cutting equipment technology, specifically to an automatic trimming device for photovoltaic module laminates. Background Technology

[0002] With the global energy structure shifting towards cleaner and lower-carbon energy, the photovoltaic (PV) industry, as a core sector of renewable energy, has achieved large-scale and rapid development. PV module laminates are the core components of PV products. After lamination, excess EVA / POE encapsulant remains at the module edges, along with issues such as burrs and dimensional deviations. These must be addressed through an edge trimming process to meet the requirements of subsequent encapsulation and installation. The processing precision, yield rate, operational safety, and efficiency of the edge trimming process directly determine the product quality and mass production capacity of PV modules.

[0003] As the photovoltaic industry develops towards larger sizes, thinner wafers, and higher power, the requirements for trimming precision and equipment safety of new high-efficiency modules such as HJT and TOPCon are becoming increasingly stringent. However, some problems still exist in the use of existing equipment, as follows:

[0004] Firstly, the loading error rate is extremely low, the false alarm rate is high, and there is a safety hazard of cutter collision. Existing trimming equipment requires manual precise positioning of the workpiece on the suction cup fixture. It is essential to ensure that the suction cup array is completely within the workpiece's projection range; otherwise, the disc cutter will directly cut into the vacuum suction cup during the trimming process, causing damage to the suction cup and equipment shutdown. However, manual precise positioning is cumbersome and significantly reduces loading efficiency. At the same time, lens reflections, dust, and foreign objects on the workpiece surface in the workshop can easily cause sensor data distortion, resulting in the problem of "falsely judging that the suction cup is out of bounds even though it is not out of bounds, causing an error and shutdown." Frequent false alarms seriously affect the continuous production capacity of the mass production line and cannot adapt to the needs of fast-paced production.

[0005] Secondly, the trimming process lacks dynamic offset control and adaptive adjustment mechanisms, making the workpiece prone to displacement and scrapping. During the trimming process, the lateral cutting force generated by the disc cutter touching the workpiece can easily cause planar displacement and edge warping. Existing equipment can only perform static fixation before loading, and lacks real-time offset detection and adjustment capabilities during the trimming process. Once offset occurs, it can cause minor issues such as trimming dimensional deviations and tempered glass chipping, or even major issues such as the cutter damaging the suction cup and the workpiece breaking and being scrapped. At the same time, existing equipment cannot synchronously adjust the workpiece position, suction cup force, and cutter position according to the real-time offset status of the workpiece, requiring manual handling after machine shutdown, resulting in low automation and a high defect rate.

[0006] In addition, existing equipment suffers from drawbacks such as poor adaptability of fixed cutting depth, lack of automatic compensation mechanism for cutter wear, and susceptibility to batch defects due to open-loop control, making it difficult to meet the current production demands of the photovoltaic industry for high precision, high flexibility, high yield, and high safety. Therefore, developing an automatic trimming device for photovoltaic module laminates with high tolerance for material feeding, low false alarm rate, dynamic offset control during the trimming process, and adaptive adjustment functions has become an urgent technical problem to be solved in the photovoltaic manufacturing field. Summary of the Invention

[0007] The purpose of this invention is to overcome the above-mentioned defects of the prior art and provide an automatic trimming device for photovoltaic module laminates. By using two progressive data corrections, the probability of misjudgment and error reporting is reduced from the source. Combined with the material feeding fault-tolerant control mechanism, it can be safely operated even with manual rough feeding. Through the dynamic posture control of trimming, the workpiece offset caused by cutting force is detected and adaptively adjusted in real time, thus solving the core pain points mentioned in the background art.

[0008] The present invention provides the following technical solution: an automatic trimming device for photovoltaic module laminates, comprising a base, a fixed frame fixedly mounted on the base, a control component mounted on the fixed frame, a first moving component mounted on the fixed frame, a second moving component fixedly mounted at the moving end of the first moving component, a motor fixedly mounted at the moving end of the second moving component, a disc cutter coaxially fixedly connected to the output end of the motor, a third moving component mounted on the base, a base plate fixedly mounted at the moving end of the third moving component, and a vacuum suction cup clamp fixedly mounted on the upper surface of the base plate.

[0009] The first moving component is used to drive the disc cutter to move up and down in the vertical direction of the Z-axis, the second moving component is used to drive the disc cutter to move horizontally in the X-axis, and the third moving component is used to drive the base plate and the vacuum suction cup clamp to feed in the horizontal direction of the Y-axis, so as to realize the independent adjustment of the workpiece position.

[0010] The control unit includes a data acquisition module, a preprocessing module, a feeding fault-tolerant control module, a trimming dynamic pose control module, a three-axis trajectory adaptive matching module, a cutting depth control module, a wear compensation and quality detection module, a risk output module, an execution drive module, and a display panel. Each module is electrically connected in sequence according to the data flow direction, and the execution drive module is electrically connected to all execution components to form a closed-loop control of the entire process.

[0011] In a preferred embodiment, the preprocessing module incorporates two progressive data correction logics: first, invalid values ​​in the original data are removed and smoothed; then, inherent system deviations and operating condition drift errors are compensated for, eliminating data distortion at the source and significantly reducing the probability of misjudgments such as material exceeding limits or workpiece offset.

[0012] In a preferred embodiment, the vacuum suction cup fixture adopts a small-size array design, with the overall projected area of ​​the suction cup array being ≤ 75% of the rated area of ​​the workpiece to be processed. This ensures, from a mechanical perspective, that the suction cup can achieve full coverage simply by placing the workpiece in the middle area of ​​the suction cup, thereby reducing the requirements for loading and alignment accuracy.

[0013] In a preferred embodiment, the feeding fault control module can realize hierarchical control of the feeding status. If the suction cup slightly exceeds the limit, the workpiece position can be automatically adjusted to compensate. Only when the suction cup is severely exceeded or the suction is abnormal will an error be triggered, thus taking into account both equipment safety and production continuity.

[0014] In a preferred embodiment, the trimming dynamic pose control module can detect the workpiece offset status in real time through dual feedback of visual contour data and suction cup negative pressure data. Slight offset can be automatically adjusted to adjust the suction force of the suction cup, the position of the workpiece and the position of the cutter without stopping the machine. Severe offset can be immediately stopped for protection, taking into account both trimming accuracy and equipment safety.

[0015] In a preferred embodiment, the three-axis trajectory adaptive matching module can automatically adapt and generate trimming trajectory and three-axis linkage parameters based on the actual pose of the workpiece, so as to realize dynamic trajectory compensation after the workpiece is offset.

[0016] In a preferred embodiment, the cutting depth control module can adjust the Z-axis height of the cutter in real time according to the workpiece surface height, adapting to the uneven glue thickness at the workpiece edge and avoiding glue residue and glass edge chipping.

[0017] In a preferred embodiment, the wear compensation and quality inspection module can automatically compensate for cutter wear, and simultaneously identify trimming defects online and automatically rework them to avoid batch defects.

[0018] The present invention has the following beneficial effects:

[0019] 1. This invention achieves safe operation by employing a triple design of small-size suction cup array mechanical design, two progressive data corrections, and graded control for fault-tolerant feeding. This design eliminates the need for precise alignment during manual feeding; the workpiece can be safely operated simply by placing it in the middle area of ​​the suction cup. The two data corrections eliminate sensor data distortion under workshop conditions, reducing the probability of false alarms due to suction cups exceeding the limit from the source. At the same time, slight over-limit situations can be automatically compensated by adjusting the workpiece position, completely avoiding the safety hazard of the cutter hitting the suction cup, and significantly improving feeding efficiency and continuous production capacity of mass production lines.

[0020] 2. This invention achieves real-time detection and closed-loop control of workpiece offset during the trimming process through a dynamic posture control system of "visual + negative pressure dual feedback + two data corrections + three-axis linkage adaptive adjustment". The two data corrections eliminate false data caused by cutting vibration and chip obstruction, accurately identify the true offset state of the workpiece. For slight offsets, the suction force of the suction cup can be automatically increased and the position of the workpiece and the cutting tool can be adjusted to complete the offset compensation without stopping the machine. For severe offsets, an emergency stop protection is immediately provided, which eliminates the problem of workpiece displacement and scrap caused by cutting force from the root and effectively reduces the workpiece scrap rate in the trimming process.

[0021] 3. This invention establishes a closed-loop electromechanical control system that integrates the entire process from data acquisition, two corrections, status judgment, decision adjustment to execution feedback. All control logic is deeply bound to and inseparable from the device's unique three-axis layout of "workpiece Y-axis movement and cutter X / Z-axis movement", replacing the open-loop control mode of existing equipment. At the same time, combined with adaptive control of cutting depth, automatic compensation for cutter wear, and online quality rework closed loop, it effectively improves the trimming yield and is fully adapted to the flexible mass production requirements of large-size, new high-efficiency photovoltaic modules. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0023] Figure 2 This is a schematic diagram of the structure of the present invention from a rear viewpoint;

[0024] Figure 3 This is a schematic diagram of the structure of the present invention from a side view.

[0025] Figure 4 This is a flowchart illustrating the logic of feeding error tolerance and trimming dynamic pose control in this invention.

[0026] Figure 5 This is a logic connection block diagram of the control component of the present invention;

[0027] Figure 6 This is a flowchart illustrating the two progressive data correction steps of the preprocessing module of this invention.

[0028] In the figure: 1. Base; 2. Fixing frame; 21. First moving component; 22. Second moving component; 3. Base plate; 31. Vacuum suction cup clamp; 32. Third moving component; 4. Control component; 5. Motor; 51. Disc cutter. Detailed Implementation

[0029] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. In addition, the forms of the various structures described in the following embodiments are merely illustrative. The automatic trimming device for photovoltaic module laminates involved in the present invention is not limited to the structures described in the following embodiments. All other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0030] Please see Figures 1-3 An automatic trimming device for photovoltaic module laminates is shown, comprising a base 1, a fixing frame 2 fixedly mounted on the base 1, a control component 4 mounted on the fixing frame 2, a first moving component 21 disposed on the fixing frame 2, a second moving component 22 fixedly mounted on the moving end of the first moving component 21, a motor 5 fixedly mounted on the moving end of the second moving component 22, a disc cutter 51 coaxially fixedly connected to the output end of the motor 5, a third moving component 32 disposed on the base 1, a base plate 3 fixedly mounted on the moving end of the third moving component 32, and a vacuum suction cup clamp 31 fixedly mounted on the upper surface of the base plate 3.

[0031] In this embodiment, it should be noted that the transmission connection of the first moving component 21, the second moving component 22, and the third moving component 32 is achieved by a linear module structure of servo motor and ball screw. The base 1, the fixed frame 2, and the base plate 3 are all welded or cast frame structures. The motor 5, the disc cutter 51, and the vacuum suction cup clamp 31 are all conventional supporting components in the photovoltaic trimming field. This embodiment does not impose specific limitations on them. Their running accuracy, cutting performance, and adsorption sealing effect can be set to match the effect of this embodiment.

[0032] It should be further explained that the first moving component 21 is used to drive the disc cutter 51 to move up and down vertically along the Z-axis, the second moving component 22 is used to drive the disc cutter 51 to move horizontally along the X-axis, and the third moving component 32 is used to drive the base plate 3 and the vacuum suction cup clamp 31 to feed horizontally along the Y-axis, so as to realize independent adjustment of the workpiece position; the control component 4 is used to collect and centrally control the operation data of the first moving component 21, the second moving component 22, the third moving component 32, the motor 5, and the vacuum suction cup clamp 31. The speed control of the disc cutter 51 adopts an independent frequency converter. The independent frequency converter is a conventional setting and is not specifically limited in this embodiment.

[0033] The control unit 4 includes a data acquisition module, a preprocessing module, a feeding error tolerance control module, a trimming dynamic pose control module, a three-axis trajectory adaptive matching module, a cutting depth control module, a wear compensation and quality detection module, a risk output module, an execution drive module, and a display panel. The output of the data acquisition module is electrically connected to the input of the preprocessing module. The output of the preprocessing module is electrically connected to the inputs of the feeding error tolerance control module and the trimming dynamic pose control module, respectively. The outputs of the feeding error tolerance control module and the trimming dynamic pose control module are both electrically connected to the input of the three-axis trajectory adaptive matching module. The output of the matching module is electrically connected to the input of the cutting depth control module. The output of the cutting depth control module is electrically connected to the input of the wear compensation and quality detection module. The output of the wear compensation and quality detection module is electrically connected to the input of the risk output module. The output of the risk output module is electrically connected to the input of the display panel. The input of the execution drive module is electrically connected to the output of each of the above functional modules. The output of the execution drive module is electrically connected to the controlled ends of the first moving component 21, the second moving component 22, the third moving component 32, the motor 5, and the vacuum suction cup clamp 31.

[0034] The device is equipped with a sensor group electrically connected to the control unit 4. The sensor group includes a vacuum pressure sensor, an upper visual positioning camera, a side tilt detection camera, a laser displacement sensor, a motor current sensor, an edge trimming quality detection camera, and a grating ruler displacement sensor.

[0035] The acquisition module collects full-dimensional data from the sensor array and outputs a raw acquisition dataset, which is the sole input for the first correction by the preprocessing module. The raw acquisition dataset includes: negative pressure data collected by the vacuum pressure sensor, workpiece contour and relative position data of the suction cup collected by the upper visual positioning camera, workpiece tilt angle data collected by the side tilt angle detection camera, workpiece height data collected by the laser displacement sensor, motor current data collected by the motor current sensor, edge image data collected by the trimming quality inspection camera, and displacement data collected by the grating ruler displacement sensor.

[0036] The preprocessing module incorporates two progressive data correction logics. Its core function is to eliminate data distortion during the loading and trimming processes, and reduce the probability of false alarms due to suction cup exceeding the boundary or workpiece misalignment. The specific process is as follows:

[0037] First data correction:

[0038] B1. Invalid Value Removal: The original dataset output by the acquisition module is used as the sole processing object, employing... The criteria remove outliers from the various types of sensor data in the original dataset to obtain a valid dataset.

[0039] Raw dataset of workpiece height acquired by laser displacement sensor For example, first calculate the arithmetic mean of the dataset. and standard deviation Set the effective threshold range as follows: Remove invalid jump point data that exceeds this range, and retain the valid height dataset. , To determine the number of valid measurement points, the contour coordinates, negative pressure, tilt angle, current, and displacement data in the original dataset are all processed using the same logic to remove invalid values ​​and integrate them to obtain the valid dataset.

[0040] B2. Sliding smoothing filter processing: Using the effective dataset obtained in step B1 as the only processing object, the 5-point moving average filter algorithm is used to smooth and denoise each type of data in the effective dataset, eliminating the small data fluctuations caused by equipment vibration, lens reflection, dust interference, and chip obstruction, and obtaining a smoothed effective dataset, which is the only input for the second correction.

[0041] With effective height dataset For example, the corrected smooth height data is calculated using the following formula:

[0042] ;

[0043] In the formula: Let be the smoothed height value of the i-th measurement point. The original height value of the i-th measurement point in the effective dataset is given; all other data in the effective dataset are smoothed using the same logic to obtain a smoothed effective dataset.

[0044] Second revised data:

[0045] C1. Static calibration deviation correction: Using the smoothed effective dataset obtained in step B2 as the sole processing object, based on the metrological calibration parameters before the equipment leaves the factory, fixed system deviation linear compensation is performed on various types of data in the smoothed effective dataset to eliminate inherent measurement errors caused by sensor installation tilt, zero drift, and coordinate system non-coincidence, thus obtaining the calibrated dataset.

[0046] Taking the contour coordinate data collected by the above visual positioning camera as an example, the coordinate offset matrix of the camera installation is obtained through calibration before leaving the factory. Contour coordinates in a smooth, effective dataset After performing matrix transformation correction, the accurate coordinates are calculated using the following formula:

[0047] ;

[0048] In the formula: These are the calibrated contour coordinates. To smooth the original contour coordinates in the valid dataset, The coordinate offset matrix is ​​pre-calibrated; the height, tilt angle, current, negative pressure, and displacement data in the smoothed effective dataset are all linearly compensated and corrected using the pre-calibrated deviation coefficients, and then integrated to obtain the calibrated dataset.

[0049] C2. Dynamic Operating Condition Compensation and Correction: Using the calibrated dataset obtained in step C1 as the sole processing object, based on the operating condition parameters such as the real-time operating temperature of the equipment, the feed speed of the moving components, and the air flow rate of the vacuum system, operating condition drift compensation is performed on various types of data in the calibrated dataset to eliminate real-time measurement errors caused by changes in operating conditions, and to obtain the final accurate dataset. This dataset is the sole basic data source for the feeding fault tolerance control module and the trimming dynamic pose control module.

[0050] Taking the current data collected by the motor current sensor as an example, based on the real-time collected motor winding temperature... Temperature drift compensation is applied to the calibrated current value, and the corrected accurate current is calculated using the following formula:

[0051] ;

[0052] In the formula: This is the accurate current value after operating condition compensation. The current values ​​in the calibrated dataset. This is the current temperature drift coefficient. For the real-time winding temperature of the motor, To calibrate the reference temperature, all other types of data in the calibrated dataset were corrected for drift using the corresponding operating condition compensation coefficients, and then integrated to obtain the final accurate dataset.

[0053] The material feeding fault tolerance control module uses the final accurate dataset as the sole basic data source to achieve fault tolerance control and reduce false alarms in manual, rough material feeding. The specific execution process is as follows:

[0054] 1. Manual loading: Simply place the photovoltaic module laminate in the middle area of ​​the suction cup array of the vacuum suction cup clamp 31. No precise alignment is required. The vacuum suction cup clamp 31 will start negative pressure adsorption.

[0055] 2. Data Acquisition and Correction: The acquisition module simultaneously acquires workpiece contour, suction cup array position, and negative pressure data. After two progressive corrections by the preprocessing module, the final accurate dataset is obtained.

[0056] 3. Safety Status Assessment:

[0057] Based on the workpiece contour coordinates and the suction cup array reference coordinates in the final accurate dataset, calculate the superboundary area of ​​the suction cup array that extends beyond the workpiece projection area. The formula is:

[0058] ;

[0059] In the formula: The total area of ​​the suction cup array. The actual area covered by the suction cup array by the workpiece is shown in mm².

[0060] Simultaneously based on the real-time negative pressure values ​​in the final accurate dataset With respect to the preset safe adsorption negative pressure threshold By comparison, we can determine whether the vacuum adsorption meets the standards.

[0061] 4. Implementation of tiered control measures:

[0062] Qualified status: When =0 and ≤ If the material is deemed to be in good condition, the equipment is allowed to start the trimming operation and continue running.

[0063] Slightly out-of-bounds state: when 0 < ≤ ( (for slight overshoot threshold) and ≤ If a slight over-limit is detected, the system will automatically adjust the workpiece's Y-axis position through the third moving component 32 to compensate for the over-limit of the suction cup. If the over-limit is detected again after compensation, the system will continue to operate.

[0064] Error reporting status: When > or > If the feeding is abnormal, an audible and visual error will be triggered and the equipment startup permission will be locked. At the same time, the specific reason for "suction cup out of bounds" or "abnormal adsorption" will be output through the display panel. The equipment can only continue to operate after manual adjustment and retesting.

[0065] It should be further noted that, in this embodiment, the overall projected area of ​​the suction cup array of the vacuum suction cup fixture 31 is ≤ 75% of the rated area of ​​the workpiece to be processed. This mechanically ensures that when the workpiece is manually placed in the middle area of ​​the suction cups, the suction cup array is completely within the workpiece's projected area. =0; Two progressive data corrections eliminate false outlines caused by lens reflections and dust, avoiding the problem of "misjudging the suction cup as being out of bounds even though it is not out of bounds" and significantly reducing the probability of false alarms.

[0066] The trimming dynamic pose control module uses the final accurate dataset as the sole basic data source to achieve real-time detection and adaptive adjustment of workpiece offset during the trimming process. The specific execution process is as follows:

[0067] 1. Real-time data acquisition and correction: During the trimming process, the upper vision positioning camera acquires the workpiece contour data in real time, and the vacuum pressure sensor acquires the suction cup negative pressure data in real time. The acquisition frequency is matched with the trimming feed speed. The acquired real-time data is synchronously sent to the preprocessing module. After two progressive corrections, a real-time accurate dataset is obtained.

[0068] 2. Offset status determination:

[0069] Based on real-time accurate datasets, calculate the real-time planar displacement of the workpiece. The formula is:

[0070] ;

[0071] In the formula: The coordinates of the workpiece's real-time contour center. These are the initial reference center coordinates of the workpiece, all in mm.

[0072] Simultaneously calculate the real-time tilt offset of the workpiece. It also monitors the real-time fluctuation range of the negative pressure value to make a dual judgment on whether the workpiece has shifted or whether the adsorption has failed.

[0073] 3. Tiered control and adaptive adjustment:

[0074] Steady state: when When the workpiece position is stable (with slight deviation from the threshold) and the negative pressure fluctuation is less than or equal to the safety threshold, the trimming operation is performed normally.

[0075] Slight offset state: when When there is a slight deviation (at the critical threshold) or a small fluctuation in negative pressure, the system determines that the workpiece has slightly deviated and simultaneously performs three adaptive adjustments: ① Automatically increase the suction negative pressure of the vacuum suction cup clamp 31 to enhance the workpiece fixing effect; ② Adjust the Y-axis position of the workpiece through the third moving component 32 to compensate for the planar offset; ③ Adjust the X-axis position of the disc cutter 51 through the second moving component 22 and adjust the Z-axis height of the cutter through the first moving component 21 to match the real-time position of the workpiece and continue the trimming operation without stopping the machine.

[0076] Severe offset state: when If the system determines that the workpiece's position is seriously abnormal, it immediately controls the first moving component 21 to drive the disc cutter 51 to lift the cutter to a safe position, suspends the three-axis feed, and triggers an audible and visual error message to prevent the cutter from damaging the suction cup and the workpiece from breaking and becoming scrap.

[0077] The three-axis trajectory adaptive matching module calculates the trimming trajectory and three-axis linkage servo execution parameters that are adapted to the actual position of the workpiece, based on the final accurate dataset and the real-time pose state of the workpiece. The calculation process is as follows:

[0078] Step 1: Construct the feature vector of the trimming trajectory, denoted as ;

[0079] In the formula: The Y-axis feed parameters for trimming the front and rear edges of the workpiece are in mm and are calculated from the actual lengths of the front and rear edges of the workpiece and the preset rated trimming allowance in the final accurate dataset. The X-axis feed parameters for trimming the left and right sides of the workpiece are in mm and are calculated from the actual length of the left and right sides of the workpiece and the preset rated trimming allowance in the final accurate dataset. The initial Z-axis height parameter of the cutter, in mm, is calculated from the initial upper surface height of the workpiece and the preset standard depth of cut in the final accurate dataset. This is the trimming feed speed parameter, in mm / s, which is a preset standard feed value based on the workpiece material and the type of excess adhesive.

[0080] Step 2: Normalization: To eliminate the dimensional differences among the components, a 4×4 diagonal normalization matrix is ​​constructed. For eigenvectors Dimensionless normalization is performed to obtain the normalized eigenvectors. ;

[0081] Normalized matrix The diagonal elements are respectively , , , ,in , , , This represents the maximum allowable value for the corresponding component of the device.

[0082] The normalization calculation formula is:

[0083] ;

[0084] result The value range of each component is [0,1].

[0085] Step 3: Weighted Processing: Set the weight vector according to the trimming accuracy priority (dimensional accuracy > depth of cut > feed rate). Construct a 4×4 diagonal weight matrix For normalized eigenvectors Perform weighted calculations to obtain weighted eigenvectors. The formula is:

[0086] ;

[0087] Step 4: Servo execution parameter mapping: Map the weighted feature vector Each component is mapped to the corresponding servo execution pulse quantity of the moving component through a pulse equivalent coefficient, as shown in the formula:

[0088] ;

[0089] ;

[0090] ;

[0091] In the formula: , , These represent the servo execution pulse quantities for the X, Y, and Z axes, respectively. , , The preset pulse equivalent coefficient, in units of pulses / mm, is determined by the servo motor parameters and the transmission ratio of the transmission mechanism; feed speed parameters. It is used to control the movement speed of each motion axis, and at the same time, it adaptively reduces the feed speed based on the workpiece posture compliance level.

[0092] The cutting depth control module, based on the final accurate dataset, performs real-time closed-loop adjustment of the 51Z axis height of the disc cutter during the trimming process. The adjustment process is as follows:

[0093] The cutting depth control module includes a height acquisition unit, a deviation calculation unit, and a synchronization adjustment unit. The height acquisition unit obtains the workpiece upper surface height value in the cutting area from the final accurate dataset. The deviation calculation unit is used to calculate the height compensation between the measured height and the reference height. The synchronization adjustment unit is based on the height compensation amount. The formula for calculating the real-time depth of cut is as follows:

[0094] ;

[0095] ;

[0096] In the formula: This is the height compensation amount, in mm; To obtain the measured height of the workpiece's upper surface in the final accurate dataset, This is the reference height of the upper surface of the workpiece; For real-time depth of cut, These are preset standard cutting depth reference values, all in mm.

[0097] Based on the calculation results, a real-time adjustment command is issued to the first moving component 21. The real-time displacement feedback of the grating ruler displacement sensor corresponding to the first moving component 21 forms a height closed-loop control, ensuring that the cutting depth is always stable at the preset reference value during the trimming process, and adapting to the uneven glue thickness at the edge of the workpiece.

[0098] The wear compensation and quality inspection module uses the final accurate dataset as a basis to dynamically compensate for the wear of the cutter and to implement closed-loop control over the trimming quality. The process is as follows:

[0099] 1. Calculation of cutter feed compensation: The current acquisition unit obtains the real-time operating current value of motor 5 from the final accurate dataset. The wear analysis unit is used to calculate the difference between the real-time operating current of the motor and the no-load reference current. Based on the current difference and the preset compensation coefficient, the cutter feed compensation is calculated. The calculation formula is as follows:

[0100] ;

[0101] In the formula: This is the cutter feed compensation amount, in mm; To obtain the real-time operating current of the motor in the final accurate dataset, This is the no-load reference current of the motor, and the unit is A. This is a preset fixed compensation coefficient, with units of mm / A; To take the absolute value.

[0102] Based on the calculation results, a compensation adjustment command is issued to the second moving component 22 to compensate for the insufficient feed caused by cutter wear.

[0103] 2. Trimming Defect Identification and Rework: The quality inspection unit obtains image data of the trimmed workpiece edge from the final accurate dataset, identifies the location and type of defects such as excess glue residue, chipped edges, and burrs, and calculates the defect rate per unit workpiece. Based on the defect location data, the rework execution unit issues rework trimming instructions to the third moving component 32 and the corresponding moving component to complete the secondary trimming of the defect location. After the secondary trimming, the defect is re-inspected by the trimming quality inspection camera until the defect is eliminated.

[0104] 3. Wear Compensation Adaptive Update: The defect detection results output by the quality inspection unit are simultaneously fed back to the wear analysis unit. When defects such as excess adhesive residue or burrs repeatedly appear at the same edge position on the same workpiece or three or more consecutive workpieces, the wear analysis unit determines the current compensation coefficient. The compensation coefficient is dynamically increased according to a preset step size because it does not match the actual wear condition of the cutter. This continues until the defect rate reported by the quality inspection unit drops below a preset threshold; simultaneously, a preset compensation coefficient is applied. The upper limit value, when If the defect rate cannot be reduced even after reaching the upper limit, a cutter replacement warning is triggered, forming a closed-loop control for wear compensation.

[0105] The risk output module is used to output the final accurate dataset, real-time pose data, material loading inspection results, trimming parameters, equipment operating status, quality inspection results, and fault warning information to the display panel in real time; the execution drive module is used to receive control commands from each functional module, send them to the corresponding execution components, and collect the action feedback signals of each execution component and send them back to the preprocessing module, forming a closed-loop control link of "data acquisition - two corrections - status judgment - decision adjustment - execution feedback".

[0106] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0107] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An automatic trimming device for photovoltaic module laminates, comprising a base (1), characterized in that: Includes a base (1), on which a fixed frame (2) is fixedly mounted, on which a control component (4) is mounted, on which a first moving component (21) is provided, a second moving component (22) is fixedly mounted at the moving end of the first moving component (21), a motor (5) is fixedly mounted at the moving end of the second moving component (22), and a disc cutter (51) is coaxially fixedly connected to the output end of the motor (5), and a third moving component (3) is provided on the base (1). 2) The moving end of the third moving component (32) is fixedly installed with a base plate (3), and a vacuum suction cup clamp (31) is fixedly installed on the upper surface of the base plate (3). The first moving component (21) is used to drive the disc cutter (51) to rise and fall along the vertical direction of the Z axis. The second moving component (22) is used to drive the disc cutter (51) to translate along the horizontal direction of the X axis. The third moving component (32) is used to drive the base plate (3) and the vacuum suction cup clamp (31) to feed along the horizontal direction of the Y axis, so as to realize the independent adjustment of the workpiece position. The control unit (4) includes a data acquisition module, a preprocessing module, a feeding error tolerance control module, a trimming dynamic pose control module, a three-axis trajectory adaptive matching module, a cutting depth control module, a wear compensation and quality detection module, a risk output module, an execution drive module, and a display panel. The output end of the data acquisition module is electrically connected to the input end of the preprocessing module. The output end of the preprocessing module is electrically connected to the input ends of the feeding error tolerance control module and the trimming dynamic pose control module, respectively. The output ends of the feeding error tolerance control module and the trimming dynamic pose control module are both electrically connected to the input end of the three-axis trajectory adaptive matching module. The output end of the three-axis trajectory adaptive matching module is electrically connected to the input end of the cutting depth control module. The output end of the cutting depth control module is electrically connected to the input end of the wear compensation and quality detection module. The output end of the wear compensation and quality detection module is electrically connected to the input end of the risk output module. The output end of the risk output module is electrically connected to the input end of the display panel. The input end of the execution drive module is electrically connected to the output ends of each of the above functional modules.

2. The automatic trimming device for photovoltaic module laminates according to claim 1, characterized in that: The acquisition module is equipped with a sensor group, which includes a vacuum pressure sensor, an upper visual positioning camera, a side tilt detection camera, a laser displacement sensor, a motor current sensor, an edge trimming quality detection camera, and a grating ruler displacement sensor. The vacuum pressure sensor is installed on the negative pressure air path main pipe of the vacuum suction cup clamp (31), and the detection end is connected to the inside of the negative pressure air path to collect the real-time negative pressure value of the vacuum suction cup clamp (31) within a unit time period; the upper visual positioning camera is installed in the middle of the crossbeam of the fixed frame (2), with the lens vertically facing the working surface of the vacuum suction cup clamp (31), to collect the planar position, edge contour and relative position data of the suction cup array of the workpiece within a unit time period; the side tilt angle detection camera is installed on the side column of the fixed frame (2), with the lens horizontally facing the working surface of the vacuum suction cup clamp (31), to collect the tilt angle data of the workpiece within a unit time period; there are two laser displacement sensors, symmetrically installed on both sides of the motor mounting base of the second moving component (22), and the disc cutter ( 51) Located on the same vertical reference plane, used to collect the height data of the upper surface of the workpiece in the cutting area within a unit time period; the motor current sensor is connected in series in the power supply circuit of the motor (5) and used to collect the real-time operating current data of the motor (5) within a unit time period; the trimming quality inspection camera is installed on the motor mounting base of the second moving component (22), with the lens facing the trimming working surface of the disc cutter (51), and used to collect the image data of the edge of the trimmed workpiece within a unit time period; there are 3 groups of grating ruler displacement sensors, which are respectively installed on the side of the guide rail of the first moving component (21), the second moving component (22), and the third moving component (32), and the reading head is fixed on the slide of the corresponding moving component, and used to collect the real-time displacement data of each moving component within a unit time period.

3. The automatic trimming device for photovoltaic module laminates according to claim 2, characterized in that: The preprocessing module incorporates two progressive data correction logics. The first correction removes invalid values ​​and performs smoothing filtering on the original dataset acquired by the acquisition module to obtain a smooth and valid dataset. The second correction uses the smooth and valid dataset as the sole input to perform static calibration deviation correction and dynamic operating condition compensation correction to obtain the final accurate dataset. The two progressive data corrections are used to eliminate data distortion during the loading and trimming processes, and reduce the probability of false alarms due to suction cup exceeding the boundary or workpiece offset. The specific process of the first correction in the preprocessing module is as follows: B1. Invalid value removal: Using the original data set output by the acquisition module as the only processing object, the 3σ criterion is used to remove outliers from the various types of sensor data in the original data set. Invalid jump point data that exceeds the threshold range are removed to obtain the valid data set. B2. Sliding smoothing filter processing: Using the effective dataset obtained in step B1 as the only processing object, the 5-point moving average filter algorithm is used to smooth and denoise each type of data in the effective dataset to obtain a smoothed effective dataset, which is the only input for the second correction.

4. The automatic trimming device for photovoltaic module laminates according to claim 3, characterized in that: The specific process of the second correction in the preprocessing module is as follows: C1. Static calibration deviation correction: Using the smoothed effective dataset obtained in step B2 as the sole processing object, based on the metrological calibration parameters before the equipment leaves the factory, fixed system deviation linear compensation is performed on various types of data in the smoothed effective dataset to obtain the calibrated dataset. C2. Dynamic Operating Condition Compensation and Correction: Using the calibrated dataset obtained in step C1 as the sole processing object, based on the operating condition parameters such as the real-time operating temperature of the equipment, the feed speed of the moving components, and the air flow of the vacuum system, operating condition drift compensation is performed on various types of data in the calibrated dataset to obtain the final accurate dataset. This dataset is the sole basic data source for the feeding fault tolerance control module and the trimming dynamic pose control module.

5. An automatic trimming device for photovoltaic module laminates according to claim 1, characterized in that: The loading fault tolerance control module, based on the final accurate dataset, determines whether the workpiece fully covers the suction cup array of the vacuum suction cup fixture (31) and whether the suction negative pressure meets the standard. The device is allowed to start only when the workpiece is placed in the middle area of ​​the suction cup and meets the safety conditions. If the deviation exceeds the threshold, an error is triggered. After correction, if the conditions are met, the device continues to run. The specific execution logic of the loading fault tolerance control module is as follows: D1. Based on the workpiece contour coordinates and suction cup array reference coordinates in the final accurate dataset, calculate the area of ​​the suction cup array that exceeds the workpiece projection area. ; Based on the real-time negative pressure value in the final accurate dataset, determine whether the vacuum adsorption meets the standard; D2. Tiered Management: When the area exceeds the boundary... When the negative pressure value is 0 and ≤ the safe adsorption negative pressure threshold, the feeding is deemed qualified and the equipment is allowed to start the trimming operation. When 0 < When the value is ≤ the slight over-limit threshold, it is determined to be a slight over-limit. The workpiece Y-axis position is automatically adjusted by the third moving component (32) to compensate for the over-limit. If the value is qualified after compensation, the operation continues. When the material feeding is slightly exceeded or the negative pressure value is not up to standard, it is judged as an abnormality, triggering an audible and visual error and locking the equipment startup permission. At the same time, the cause of the abnormality is output through the display panel.

6. The automatic trimming device for photovoltaic module laminates according to claim 4, characterized in that: The output of the execution drive module is electrically connected to the controlled ends of the first moving component (21), the second moving component (22), the third moving component (32), the motor (5), and the vacuum suction cup clamp (31), respectively. The trimming dynamic pose control module, based on the final accurate dataset, judges the workpiece offset state in real time through dual feedback of visual contour data and suction cup negative pressure data, and links the execution drive module to adjust the workpiece position, suction cup suction force, and corresponding position of the disc cutter (51). The specific execution logic of the trimming dynamic pose control module is as follows: E1. During the trimming process, the acquisition module collects workpiece contour data and suction cup negative pressure data in real time. After being corrected twice by the preprocessing module, a real-time accurate dataset is obtained. E2. Calculate the real-time planar displacement of the workpiece based on a real-time accurate dataset. With tilt offset Simultaneously determine the fluctuation range of the negative pressure value; E3. Tiered Management: When When the position is determined to be stable and the negative pressure fluctuation is ≤ the slight deviation threshold and ≤ the safety threshold, the trimming operation can be performed normally; when When the deviation threshold is ≤ or the negative pressure fluctuates slightly, a slight deviation is determined. The suction negative pressure of the vacuum suction cup clamp (31) is automatically increased. The workpiece Y-axis position is adjusted by the third moving component (32), the X-axis position of the disc cutter (51) is adjusted by the second moving component (22), and the Z-axis height of the cutter is adjusted by the first moving component (21). After compensating for the deviation, the trimming continues. When the deviation from the threshold is severe, the position is determined to be seriously abnormal. The disc cutter (51) is immediately controlled to lift to a safe position, the three-axis feed is paused, and an audio-visual error is triggered.

7. An automatic trimming device for photovoltaic module laminates according to claim 5, characterized in that: The three-axis trajectory adaptive matching module calculates the trimming trajectory and three-axis linkage servo execution parameters that are adapted to the actual position of the workpiece based on the final accurate dataset and the workpiece pose state. Through normalization processing and weighted calculation, the trimming parameters are mapped to the servo execution pulse quantity of the corresponding moving component. At the same time, the feed speed is adaptively adjusted based on the pose compliance level.

8. An automatic trimming device for photovoltaic module laminates according to claim 4, characterized in that: The cutting depth control module adjusts the Z-axis height of the disc cutter (51) in real time based on the workpiece upper surface height data in the final accurate dataset. It obtains the real-time cutting depth through the height compensation calculation formula and sends adjustment instructions to the first moving component (21). The height closed-loop control is formed through the feedback of the grating ruler displacement sensor.

9. An automatic trimming device for photovoltaic module laminates according to claim 4, characterized in that: The wear compensation and quality inspection module calculates the cutter wear feed compensation amount and issues adjustment commands based on the motor operating current data and trimming edge image data in the final accurate dataset. At the same time, it identifies the location of trimming defects and automatically completes secondary rework trimming. Based on the defect detection results, it updates the compensation coefficient in reverse, forming a complete closed loop of wear compensation and quality control.

10. An automatic trimming device for photovoltaic module laminates according to claim 1, characterized in that: The vacuum suction cup fixture (31) adopts a multi-suction cup unit array combination design. The overall projected area of ​​the suction cup array is ≤ 75% of the rated area of ​​the photovoltaic module laminate to be processed, and the outer contour size of the suction cup array is smaller than the inner contour size of the smallest specification workpiece to be processed. The risk output module is used to output the final accurate dataset, real-time pose data, material loading detection results, trimming parameters, equipment operating status, and fault warning information to the display panel in real time. The execution drive module collects the action feedback signals of each execution component and sends them back to the preprocessing module to form a closed-loop control link for the entire process.

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