A flexible solar cell array trial production detection workbench and detection method

Abstract

The application discloses a flexible solar cell array trial production and detection workbench and a detection method, which comprises a top support, a movable bottom support, a cell array processing table, a plurality of lifting columns, an XY-axis bidirectional moving sliding table, an image acquisition module and a control system; the cell array processing table is installed on the top support; the top support is erected above the movable bottom support through the plurality of lifting columns; the plurality of lifting columns are electrically connected with the control system; the XY-axis bidirectional moving sliding table is installed at the bottom of the top support; the image acquisition module is installed on the XY-axis bidirectional moving sliding table; and the control system is electrically connected with the XY-axis bidirectional moving sliding table. The application realizes integrated operation of flexible solar cell array production and detection, effectively reduces damage caused by product carrying and transfer, improves detection automation level and detection precision, simultaneously reduces labor cost of production and detection, and is suitable for trial production and production requirements of large quantities of flexible solar cell arrays.

Description

Technical Field

[0001] This invention relates to the technical field of flexible solar cell array production, manufacturing, and testing, and in particular to a flexible solar cell array prototype testing workbench and testing method. Background Technology

[0002] Flexible solar cell arrays represent a cutting-edge research direction in the field of solar cells. With their advantages of lightweight, thinness, high density, long on-orbit service life, and reusability, they hold great promise for applications in the aerospace industry. As the application scenarios for flexible solar cell arrays continue to expand, the photoelectric conversion efficiency of the cells is continuously improving. The increasing power demands of spacecraft are also driving a significant increase in the number of cells deployed in these arrays. This places higher demands on the production efficiency and testing accuracy of flexible solar cell arrays.

[0003] Currently, the production and testing processes for flexible solar cell arrays still face numerous technical challenges, specifically:

[0004] 1. The bonding of the battery array requires the application of fishbone glue to the substrate using a mold and scraper. However, fishbone glue is prone to defects such as poor glue retention, uneven application, and internal air bubbles. These defects are difficult to detect by manual front inspection after the battery cell assembly is bonded. This can easily lead to bonding failure and cell cracking in the flexible solar cell array under alternating hot and cold environments, ultimately causing the battery array's electrical performance to degrade.

[0005] 2. There is currently no dedicated operating table in the industry suitable for flexible solar cell arrays. The inspection of the back adhesive and appearance needs to be completed manually by flipping the cell array. Moreover, the entire production and inspection process requires frequent changes of dedicated production tooling and multiple handling and transfers. This series of operations greatly increases the probability of cell cracking and substrate damage.

[0006] 3. Existing testing methods lack integrated equipment support, making it impossible to accurately test the back coating of flexible solar cell arrays, or to complete high-precision appearance inspection of the front and back of the arrays. The overall testing capability cannot meet the current production and testing quality requirements of flexible solar cell arrays.

[0007] Based on the aforementioned technical pain points in the industry, a flexible solar cell array prototype testing workbench integrating production operation and appearance inspection was developed, along with testing methods based on this workbench. This has significant engineering application value for improving the production efficiency of flexible solar cell arrays, reducing product damage rate, and improving testing accuracy. Summary of the Invention

[0008] The purpose of this invention is to overcome the shortcomings of the prior art and provide a flexible solar cell array trial production and testing workbench and testing method, so as to realize the integrated operation of flexible solar cell array production and testing, effectively reduce the damage caused by product handling and transfer, improve the level of automation and accuracy of testing, and reduce the labor cost of production and testing, and adapt to the needs of large-scale trial production and production of flexible solar cell arrays.

[0009] The objective of this invention is achieved through the following technical solution:

[0010] A flexible solar array prototype testing workbench includes a top support, a movable bottom support, a solar array processing table, multiple lifting columns, an XY-axis bidirectional sliding table, an image acquisition module, and a control system. The solar array processing table is mounted on the top support and is used to hold the solar array. The top support is supported above the movable bottom support by multiple lifting columns. Each lifting column is electrically connected to the control system, which controls the synchronous lifting and lowering of the columns, thereby driving the solar array processing table to move up and down. The XY-axis bidirectional sliding table is mounted on the bottom of the top support. The image acquisition module is mounted on the XY-axis bidirectional sliding table and is used to move along a preset path and capture images of the solar array area by area. The control system is electrically connected to the XY-axis bidirectional sliding table and controls the XY-axis bidirectional sliding table to move the image acquisition module along the X and Y axes.

[0011] Furthermore, the XY-axis bidirectional sliding slide includes an X-axis slide and a Y-axis slide, whose movements are independent of each other. The Y-axis slide includes two Y-axis slide rails, two Y-axis sliders, a U-shaped bracket, and a Y-axis servo motor. The two Y-axis slide rails are symmetrically installed on the front and rear sides of the bottom of the top bracket, and the two Y-axis sliders are respectively installed on the two Y-axis slide rails. The two sides of the U-shaped bracket are respectively connected to the two Y-axis sliders. The Y-axis servo motor is driven by the two Y-axis sliders and electrically connected to the control system, driving the two Y-axis sliders to move along the Y-axis slide rails. The X-axis slide includes an X-axis slide rail, an X-axis slider, and an X-axis servo motor. The X-axis slide rail is installed on the bottom edge of the U-shaped bracket, and the X-axis slider is installed on the X-axis slide rail. The X-axis servo motor is driven by the X-axis slider and electrically connected to the control system, driving the X-axis slider to move along the X-axis slide rail.

[0012] Furthermore, the image acquisition module is mounted on the X-axis slider via an L-shaped bracket.

[0013] Furthermore, the movable bottom support includes a bottom support and swivel casters disposed on the bottom surface of the bottom support.

[0014] Furthermore, it also includes a supplementary lighting module, which is installed on a movable bottom bracket and electrically connected to the control system. The control system adjusts the opening and closing and brightness of the supplementary lighting module according to the light intensity of the on-site working environment to ensure the imaging quality of the image acquisition module.

[0015] Furthermore, the supplementary lighting module includes multiple strip LED lights, which are arranged circumferentially around the top edge of the movable bottom bracket.

[0016] Furthermore, the battery array processing table includes a tabletop frame, high-transparency tempered glass, and handrails. The high-transparency tempered glass is embedded in the tabletop frame, and the handrails are fixedly connected to the left and right sides of the tabletop frame.

[0017] Furthermore, the image acquisition module is an industrial camera.

[0018] Furthermore, the top support is provided with a limiting structure around its perimeter to achieve positioning and prevent detachment of the battery array processing table; the battery array processing table is installed on the top support, and shock-absorbing rubber is bonded to the contact surface between the battery array processing table and the top support, and the surface of the shock-absorbing rubber is machined with anti-slip grooves.

[0019] A testing method based on the aforementioned flexible solar cell array prototype testing station includes the following steps:

[0020] Loading and fixing: Place the battery array on the battery array processing table;

[0021] Zoned photography: The control system controls the bidirectional XY axis moving slide to drive the image acquisition module to move along a preset path and photograph the back of the battery array zone by zone; the image acquisition module transmits the image data to an external computer in real time, and the external computer stitches the images to generate a back appearance image covering the entire battery array.

[0022] Backside adhesive defects: View the backside appearance of the spliced ​​battery array using an external computer, identify fishbone-shaped adhesive defects on the backside of the battery array, and record the defect type;

[0023] Front appearance inspection: The control system controls the lifting column to descend to the preset operating height, and the battery array is manually inspected by the naked eye on the battery array processing table. The front appearance defects of the battery cells, substrate and components of the battery array are detected, and the defect locations are marked and recorded.

[0024] Backside manual inspection: The control system controls the lifting column to rise to the preset operating height, and controls the XY axis bidirectional moving slide to move the image acquisition module to the right edge of the battery array processing table; the backside of the battery array is observed by a person in a non-contact manner to check for defects in the backside of the fishbone glue, substrate, battery cells and components, and the defect locations are marked and recorded.

[0025] Inspection Archiving: Organize and archive the appearance image data, defect marking information, and manual inspection records from the external computer.

[0026] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0027] 1. It enables integrated production and testing operations. Flexible solar cell arrays can complete production processes such as substrate coating, cell assembly bonding, and welding of various electrical components on this workbench. Alternatively, the entire cell array processing table can be disassembled and transferred to other workstations such as a negative pressure platform for subsequent operations. During the testing process, whether it is front appearance inspection or back adhesive type inspection, there is no need to frequently move or flip the cell array body, which effectively reduces the risk of substrate damage and cell cracking during handling or flipping.

[0028] 2. Improve the level of automation in inspection. Through the precise cooperation of industrial cameras and XY-axis bidirectional moving slides, high-definition imaging of the back of the battery array can be achieved, which can complete the automated initial inspection of the back adhesive, replacing the traditional manual visual observation and manual photography, saving manpower and time costs, and avoiding accidental damage to the battery array caused by close contact with personnel.

[0029] 3. High operational comfort and adaptability: The four lifting columns are raised and lowered synchronously through the control system, which can realize a wide range of height adjustment of the battery array processing table, allowing operators to complete production and testing operations in a labor-saving manner; the universal casters at the bottom enable the worktable to move in all directions, which can flexibly adapt to different production plant layouts, making it highly adaptable.

[0030] 4. Controllable supplementary lighting and imaging effects: The brightness of the strip LED light is adjustable, and precise supplementary lighting can be adjusted according to the lighting conditions of different production plants to ensure the imaging quality of the industrial camera; The vertical distance between the industrial camera and the processing table is constant, eliminating the need to purchase expensive automatic zoom or large-area industrial cameras. A conventional fixed-focus industrial camera can be used to complete the shooting and inspection of large-area flexible solar cell arrays, effectively controlling equipment manufacturing costs.

[0031] 5. High comprehensiveness and accuracy of inspection: The supporting inspection methods enable multi-round, all-round inspection of the front and back of the flexible solar cell array, covering all dimensions of inspection, including the adhesive, cells, substrate, and various components. Combining machine-generated initial inspection with manual fine-tuning, it can identify the location of defects in the cell array earlier and more comprehensively, facilitating subsequent repair and replacement. At the same time, the photographed image data and defect marking information can be directly archived and stored on an external computer, enabling traceability of production inspection data and providing data support for the production quality control of flexible solar cell arrays. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the overall structure of the testing workbench of the present invention.

[0033] Figure 2 This is a schematic diagram of the structure of the testing workbench of the present invention, excluding the battery array processing stage.

[0034] Figure 3 This is a schematic diagram of the battery array processing stage in this invention.

[0035] Figure 4 This is a flowchart of the detection method of the present invention. Detailed Implementation

[0036] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of the present invention, but not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0037] like Figures 1 to 3 As shown, this embodiment provides a flexible solar cell array prototype testing workbench, including a top support 1, a movable bottom support 2, a cell array processing table 3, multiple lifting columns 4, an XY-axis bidirectional moving slide 5, an image acquisition module 6, and a control system (not shown in the figure). The cell array processing table 3 is mounted on the top support 1 and is used to place the cell array. The top support 1 is supported above the movable bottom support 2 by multiple lifting columns 4. The multiple lifting columns 4 are all electrically connected to the control system, which controls the multiple lifting columns 4 to move up and down synchronously, thereby driving the cell array processing table 3 to move up and down. By synchronously controlling the lifting columns 4, the horizontality and stability of the cell array processing table 3 during the lifting process are ensured. The XY-axis bidirectional moving slide 5 is mounted on the bottom of the top support 1. The image acquisition module 6 is mounted on the XY-axis bidirectional moving slide 5 and is used to move along a preset path and capture images of the cell array area by area. The control system is electrically connected to the XY-axis bidirectional moving slide 5, which controls the XY-axis bidirectional moving slide 5 to drive the image acquisition module 6 to move along the X and Y axes.

[0038] In a specific example, the XY-axis bidirectional sliding stage 5 includes an X-axis slide and a Y-axis slide, whose movements are independent of each other to ensure the positioning accuracy of the industrial camera. The Y-axis slide includes two Y-axis slide rails 501, two Y-axis sliders (not shown in the figure), a U-shaped bracket 502, and a Y-axis servo motor (not shown in the figure). The two Y-axis slide rails 501 are symmetrically mounted on the front and rear sides of the bottom of the top bracket 1, and the two Y-axis sliders are respectively mounted on the two Y-axis slide rails 501. The two sides of the U-shaped bracket 502 are respectively connected to the two Y-axis sliders. The system is connected to the Y-axis servo motor, which is driven by two Y-axis sliders and electrically connected to the control system. The Y-axis servo motor drives the two Y-axis sliders to move along the Y-axis slide rail 501. The X-axis slide includes an X-axis slide rail 503, an X-axis slider (not shown in the figure), and an X-axis servo motor. The X-axis slide rail 503 is mounted on the bottom edge of the U-shaped bracket 502, and the X-axis slider is mounted on the X-axis slide rail 503. The X-axis servo motor is driven by the X-axis slider and electrically connected to the control system. The X-axis servo motor drives the X-axis slider to move along the X-axis slide rail 503.

[0039] In a specific example, the image acquisition module 6 is mounted on the X-axis slider via an L-shaped bracket 7.

[0040] In a specific example, the image acquisition module 6 is a fixed-focus industrial camera with its lens vertically facing the battery array processing table 3, and the vertical distance between the industrial camera and the battery array processing table 3 is constant.

[0041] In a specific example, a supplementary lighting module 8 is also included. The supplementary lighting module 8 is mounted on a movable bottom bracket 2 and electrically connected to the control system. The control system adjusts the opening and closing and brightness of the supplementary lighting module 8 according to the light intensity of the on-site working environment, so as to provide supplementary lighting for the industrial camera to take pictures and ensure the imaging quality of the image acquisition module 6.

[0042] In one specific example, the supplementary lighting module 8 includes multiple strip LED lights arranged circumferentially around the top edge of the movable bottom bracket 2, and each light strip is fixed to the bottom bracket 201 by adhesive or bolts.

[0043] In a specific example, the battery array processing table 3 includes a table frame 301, high-transmittance tempered glass 302, and handrails 303. The high-transmittance tempered glass 302 is embedded in the table frame 301. The thickness of the high-transmittance tempered glass 302 is 10mm~12mm, preferably 11mm, to ensure the light transmittance of the industrial camera while ensuring the load-bearing capacity and structural rigidity. The handrails 303 are fixedly connected to the left and right sides of the table frame 301 to facilitate the handling by the operator.

[0044] In a specific example, the top support 1 is provided with a limiting structure 101 around its perimeter to achieve positioning and anti-detachment of the battery array processing table 3, thereby achieving precise positioning of the battery array processing table 3. The battery array processing table 3 is installed on the top support 1, and shock-absorbing rubber (not shown in the figure) is bonded to the contact surface between the battery array processing table 3 and the top support 1. The surface of the shock-absorbing rubber is processed with anti-slip grooves to effectively buffer the vibration generated during the movement or lifting of the worktable and prevent damage to the appearance of the battery array.

[0045] In a specific example, the movable bottom support 2 includes a bottom support 201 and omnidirectional casters 202 disposed on the bottom surface of the bottom support 201, which can realize the omnidirectional movement of the workbench and can be locked and fixed at any position, making it easy to flexibly adjust the placement of the workbench and adapt to different production plant layouts.

[0046] like Figure 4 As shown, this embodiment also provides a testing method based on the above-described flexible solar cell array prototype testing station, including the following steps:

[0047] Loading and fixing: Place the battery array stably on the battery array processing table 3;

[0048] Zoned photography: The control system controls the XY axis bidirectional moving slide 5 to drive the image acquisition module 6 to move along the preset path and photograph the back of the battery array zone by zone; if the light source in the on-site working environment is insufficient, the supplementary light module 8 is activated and adjusted to a suitable brightness to supplement the light for photography; the image acquisition module 6 transmits the image data to the external computer in real time, and the external computer stitches the images to generate a back appearance image covering the entire battery array.

[0049] Back-side adhesive pattern inspection: View the back-side appearance image of the spliced ​​battery array through an external computer, identify fishbone-like adhesive pattern defects on the back of the battery array, such as poor adhesive pattern retention, uneven adhesive application, and the presence of air bubbles, and mark the defect location and record the defect type.

[0050] Front appearance inspection: The lifting column 4 is lowered to the preset operating height by the control system. The battery array is then visually inspected on the battery array processing table 3. The front appearance defects of the battery cells, substrate and components of the battery array are detected, and the defect locations are marked and recorded.

[0051] Manual inspection of the back side: The control system controls the lifting column 4 to rise to the preset operating height, and controls the XY axis bidirectional moving slide 5 to move the image acquisition module 6 to the right edge of the battery array processing table 3; the operator enters the bottom of the worktable and manually observes the back of the battery array in a non-contact manner, checking for appearance problems such as damage to the back of the back of the fishbone glue, substrate, battery cells and components, and marking and recording the defect locations.

[0052] Inspection Archiving: The appearance image data, defect marking information, and manual inspection records from the external computer are uniformly organized, archived, and stored in the production quality control system to achieve traceability of inspection data.

[0053] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope disclosed in the present invention, based on the technical solution and inventive concept of the present invention, shall fall within the scope of protection of the present invention.

Claims

1. A flexible solar cell array prototype testing workbench, characterized in that: The system includes a top support, a movable bottom support, a battery array processing table, multiple lifting columns, an XY-axis bidirectional sliding table, an image acquisition module, and a control system. The battery array processing table is mounted on the top support and is used to hold the battery array. The top support is supported above the movable bottom support by multiple lifting columns. Each lifting column is electrically connected to the control system, which controls the synchronous lifting and lowering of the columns, thereby driving the battery array processing table to move up and down. The XY-axis bidirectional sliding table is mounted on the bottom of the top support. The image acquisition module is mounted on the XY-axis bidirectional sliding table and is used to move along a preset path and capture images of the battery array area by area. The control system is electrically connected to the XY-axis bidirectional sliding table and controls the XY-axis bidirectional sliding table to move the image acquisition module along the X and Y axes.

2. The flexible solar cell array prototype testing platform according to claim 1, characterized in that: The XY-axis bidirectional sliding slide includes an X-axis slide and a Y-axis slide, whose movements are independent of each other. The Y-axis slide includes two Y-axis slide rails, two Y-axis sliders, a U-shaped bracket, and a Y-axis servo motor. The two Y-axis slide rails are symmetrically installed on the front and rear sides of the bottom of the top bracket, and the two Y-axis sliders are respectively installed on the two Y-axis slide rails. The two sides of the U-shaped bracket are respectively connected to the two Y-axis sliders. The Y-axis servo motor is driven by the two Y-axis sliders and electrically connected to the control system, driving the two Y-axis sliders to move along the Y-axis slide rails. The X-axis slide includes an X-axis slide rail, an X-axis slider, and an X-axis servo motor. The X-axis slide rail is installed on the bottom edge of the U-shaped bracket, and the X-axis slider is installed on the X-axis slide rail. The X-axis servo motor is driven by the X-axis slider and electrically connected to the control system, driving the X-axis slider to move along the X-axis slide rail.

3. The flexible solar cell array prototype testing platform according to claim 2, characterized in that: The image acquisition module is mounted on the X-axis slider via an L-shaped bracket.

4. The flexible solar cell array prototype testing platform according to claim 1, characterized in that: The movable bottom support includes a bottom support and swivel casters disposed on the bottom surface of the bottom support.

5. The flexible solar cell array prototype testing platform according to claim 1, characterized in that: It also includes a supplementary lighting module, which is installed on a movable bottom bracket and electrically connected to the control system. The control system adjusts the opening and closing and brightness of the supplementary lighting module according to the light intensity of the on-site working environment to ensure the imaging quality of the image acquisition module.

6. The flexible solar cell array prototype testing platform according to claim 5, characterized in that: The supplementary lighting module includes multiple strip LED lights, which are arranged circumferentially around the top edge of the movable bottom bracket.

7. The flexible solar cell array prototype testing platform according to claim 1, characterized in that: The battery array processing table includes a table frame, high-transparency tempered glass, and handrails. The high-transparency tempered glass is embedded in the table frame, and the handrails are fixedly connected to the left and right sides of the table frame.

8. The flexible solar cell array prototype testing platform according to claim 1, characterized in that: The image acquisition module is an industrial camera.

9. The flexible solar cell array prototype testing platform according to claim 1, characterized in that: The top support is equipped with a limiting structure around its perimeter to position and prevent the battery array processing table from detaching. The battery array processing table is mounted on the top support, and shock-absorbing rubber is bonded to the contact surface between the battery array processing table and the top support. The surface of the shock-absorbing rubber is machined with anti-slip grooves.

10. A testing method based on the flexible solar cell array prototype testing station according to any one of claims 1 to 9, characterized in that, Including steps, Loading and fixing: Place the battery array on the battery array processing table; Zoned photography: The control system controls the bidirectional XY axis moving slide to drive the image acquisition module to move along a preset path and photograph the back of the battery array zone by zone; the image acquisition module transmits the image data to an external computer in real time, and the external computer stitches the images to generate a back appearance image covering the entire battery array. Backside adhesive defects: View the backside appearance of the spliced ​​battery array using an external computer, identify fishbone-shaped adhesive defects on the backside of the battery array, and record the defect type; Front appearance inspection: The control system controls the lifting column to descend to the preset operating height, and the battery array is manually inspected by the naked eye on the battery array processing table. The front appearance defects of the battery cells, substrate and components of the battery array are detected, and the defect locations are marked and recorded. Backside manual inspection: The control system controls the lifting column to rise to the preset operating height, and controls the XY axis bidirectional moving slide to move the image acquisition module to the right edge of the battery array processing table; the backside of the battery array is observed by a person in a non-contact manner to check for defects in the backside of the fishbone glue, substrate, battery cells and components, and the defect locations are marked and recorded. Inspection Archiving: Organize and archive the appearance image data, defect marking information, and manual inspection records from the external computer.

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