Photovoltaic module lamination process, system, and electronic device

Abstract

The application provides a photovoltaic module laminating method, system and electronic equipment, and relates to the technical field of photovoltaic module production. The method embeds a thin film pressure sensor in the interior of an experimental photovoltaic module for in-situ monitoring, acquires the pressure distribution and stress change characteristics of the cell sheet in the laminating process by using the real-time collected pressure difference, accurately identifies abnormal areas of local stress concentration, uneven pressure and exceeding the safety critical threshold, and can dynamically optimize and adjust the adhesive film filling parameters corresponding to the abnormal areas according to the pressure difference, thereby reducing the occurrence probability of hidden crack and broken piece defects from the source, and improving the stability of the laminating process and the product yield.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic module manufacturing technology, and in particular to a photovoltaic module lamination process method, system and electronic equipment. Background Technology

[0002] In the production process of photovoltaic modules, the lamination of cell electrodes still requires manual observation of the lamination results to deduce the cause of lamination abnormalities. Because lamination involves numerous factors such as lamination parameters, raw materials, and tooling, reverse deduction requires significant manpower, resources, and time to find the cause of the abnormality. This leads to poor stability in the photovoltaic module lamination process and affects the consistency of product quality. Furthermore, the process of handling lamination abnormalities relies on manual experience, which is highly subjective and has low accuracy. Summary of the Invention

[0003] In view of this, the purpose of the present invention is to provide a method, system and electronic device for photovoltaic module lamination. The method embeds a thin-film pressure sensor inside the experimental photovoltaic module for in-situ monitoring, and uses the real-time collected pressure difference value to obtain the pressure distribution and stress change characteristics of the cells during the lamination process. It can accurately identify local stress concentration, pressure unevenness and abnormal areas that exceed the safety critical threshold, and can dynamically optimize and adjust the film filling parameters corresponding to the abnormal areas according to the pressure difference value. This reduces the probability of microcracks and cell breakage defects from the source, and improves the stability of the lamination process and the product yield.

[0004] In a first aspect, embodiments of the present invention provide a photovoltaic module lamination process, the method comprising: The encapsulant film is filled into the cell array of the current photovoltaic module according to the target filling parameters; When laminating the current photovoltaic module, the pressure difference between adjacent pressure detection points is calculated in real time using the thin-film pressure sensor in the current photovoltaic module. When the pressure difference is detected to be greater than the preset difference threshold, the abnormal area of ​​the encapsulant film of the current photovoltaic module is obtained according to the pressure detection point corresponding to the pressure difference, and the filling and updating strategy of the abnormal area of ​​the encapsulant film is determined based on the pressure difference. The target filling parameters are updated using a filling update strategy. After the encapsulant film is filled into the cell array of the next photovoltaic module according to the updated target filling parameters, the next photovoltaic module is laminated.

[0005] Optionally, the step of filling the encapsulant film into the cell array of the current photovoltaic module according to the target filling parameters includes: Obtain the cell array, glass cover, and photovoltaic backsheet in the current photovoltaic module, and determine the target filling parameters of the encapsulant film based on the encapsulant film filling area between the glass cover and the photovoltaic backsheet; Based on the film filling area, the thin film pressure sensor is deployed in the current photovoltaic module so that the pressure detection point of the thin film pressure sensor covers at least the cell string spacing area, the cell spacing area and the opening area of ​​the photovoltaic backsheet. Fill the adhesive film into the adhesive film filling area according to the target filling parameters.

[0006] Optionally, the step of calculating the pressure difference between adjacent pressure detection points in real time using a thin-film pressure sensor in the current photovoltaic module during the lamination process includes: Based on the pressure detection points covered by the battery string spacing region, the battery cell spacing region, and the opening region, the first pressure detection point set corresponding to the battery string spacing region, the second pressure detection point set corresponding to the battery cell spacing region, and the third pressure detection point set corresponding to the battery cell spacing region in the thin film pressure sensor are obtained respectively. When lamination is detected in the current photovoltaic module, the pressure values ​​of each pressure detection point in the first pressure detection point set, the second pressure detection point set, and the third pressure detection point set are acquired in real time. The first pressure difference is determined by the pressure difference between adjacent pressure detection points in the first pressure detection point set, the second pressure difference is determined by the pressure difference between adjacent pressure detection points in the second pressure detection point set, and the third pressure difference is determined by the pressure difference between adjacent pressure detection points in the third pressure detection point set, ...

[0007] Optionally, when a pressure difference is detected to be greater than a preset difference threshold, the abnormal area of ​​the encapsulant film of the current photovoltaic module is obtained based on the pressure detection point corresponding to the pressure difference, including: Obtain a first difference threshold, a second difference threshold, and a third difference threshold corresponding to the battery string spacing region, the battery cell spacing region, and the opening region; wherein, the first difference threshold is less than the second difference threshold, and the second difference threshold is less than the third difference threshold; When the first pressure difference is detected to be greater than the first difference threshold, the first pressure test point corresponding to the first pressure difference in the first pressure detection point set is obtained, and the first abnormal area of ​​the adhesive film in the battery string spacing area is obtained through the first pressure test point. When the second pressure difference is detected to be greater than the second difference threshold, the second pressure test point corresponding to the second pressure difference in the second pressure detection point set is obtained, and the second film abnormal area in the cell spacing area is obtained through the second pressure test point. When the detected third pressure difference is greater than the third difference threshold, the third pressure test point corresponding to the third pressure difference in the third pressure detection point set is obtained, and the third film abnormal area in the opening area is obtained through the third pressure test point.

[0008] Optionally, the filling and renewal strategy for abnormal areas of the adhesive film can be determined based on the pressure difference, including: Based on the first pressure difference, determine the first adhesive film filling amount in the first adhesive film abnormal area in the battery string spacing region; Based on the second pressure difference, the amount of second adhesive film filling in the abnormal area of ​​the second adhesive film in the cell spacing region is determined. Based on the third pressure difference, determine the third adhesive film filling amount and the opening degree value of the third adhesive film abnormal area in the opening area; The filling and renewal strategy for each abnormal area of ​​the adhesive film is determined by the filling amount of the first adhesive film, the filling amount of the second adhesive film, the filling amount of the third adhesive film, and the aperture value.

[0009] Optionally, the target fill parameters are updated using a fill update strategy, including: When the pressure value at the pressure detection point in the opening area is less than the preset pressure threshold, the target encapsulant filling amount and the target opening degree of the photovoltaic backsheet are determined based on the filling update strategy. The film filling value of the opening area is calculated using the target film filling amount, and the sealing target value of the opening area is calculated using the target opening size value. The target filling parameters are updated based on the film filling value and the sealing target value.

[0010] Optionally, after filling the encapsulant film into the cell array of the next photovoltaic module according to the updated target filling parameters, the next photovoltaic module is laminated, including: Obtain the next photovoltaic module of the same model as the current photovoltaic module, and determine the target glass cover, target cell array and target photovoltaic backsheet to be stacked sequentially in the next photovoltaic module; Obtain the target filling area of ​​the encapsulant film between the target glass cover and the target photovoltaic backsheet, and fill the encapsulant film into the target filling area using the updated target filling parameters; After detecting that the encapsulant film in the next photovoltaic module has been completely filled, lamination is performed on the next photovoltaic module.

[0011] Optionally, after detecting that the encapsulant film in the next photovoltaic module has been completely filled and performing a lamination process on the next photovoltaic module, the method further includes: Obtain the target pressure sensor in the next photovoltaic module, and use the target pressure sensor to obtain the first pressure value and the second pressure value between adjacent pressure detection points in the opening area; wherein, the target pressure sensor and the thin film pressure sensor are of the same model and are deployed in the same location; Calculate the pressure difference between the first pressure value and the second pressure value, and obtain the minimum pressure value between the first pressure value and the second pressure value; The pressure difference between adjacent pressure detection points is determined by the ratio of the pressure difference to the minimum pressure value. When the pressure difference exceeds the preset difference threshold, the filling update strategy is updated based on the pressure difference, and the target filling parameters are updated using the filling update strategy.

[0012] In a second aspect, the present invention provides a photovoltaic module lamination system, the system comprising: Initial filling processing module: used to fill the encapsulant film into the cell array of the current photovoltaic module according to the target filling parameters; Pressure difference calculation module: used to calculate the pressure difference between adjacent pressure detection points in real time using the thin film pressure sensor in the current photovoltaic module when laminating the current photovoltaic module; Strategy update processing module: When the detected pressure difference is greater than the preset difference threshold, it obtains the current abnormal area of ​​the encapsulant film of the photovoltaic module according to the pressure detection point corresponding to the pressure difference, and determines the filling update strategy of the abnormal area of ​​the encapsulant film based on the pressure difference. The lamination update processing module is used to update the target filling parameters using a filling update strategy, fill the encapsulant film into the cell array of the next photovoltaic module according to the updated target filling parameters, and perform lamination processing on the next photovoltaic module.

[0013] Thirdly, embodiments of the present invention also provide an electronic device, which includes a processor and a memory, the memory storing computer-executable instructions that can be executed by the processor, and the processor executing the computer-executable instructions to implement the steps of the photovoltaic module lamination method provided in the first aspect.

[0014] This invention provides a photovoltaic module lamination method, system, and electronic device. During the lamination process, the method first fills the cell array of the current photovoltaic module with an encapsulant film according to target filling parameters. Then, during lamination, a thin-film pressure sensor in the current photovoltaic module calculates the pressure difference between adjacent pressure detection points in real time. When the detected pressure difference exceeds a preset threshold, an abnormal area of ​​the encapsulant film in the current photovoltaic module is identified based on the pressure detection point corresponding to the pressure difference, and a filling update strategy for this abnormal area is determined based on the pressure difference. Finally, the target filling parameters are updated using the filling update strategy, and the encapsulant film is filled into the cell array of the next photovoltaic module according to the updated target filling parameters before lamination of the next photovoltaic module. This method uses a thin-film pressure sensor embedded inside the experimental photovoltaic module for in-situ monitoring. By acquiring the pressure difference in real time, it obtains the pressure distribution and stress change characteristics of the cells during the lamination process, accurately identifies abnormal areas such as local stress concentration, uneven pressure, and areas exceeding the safety threshold, and can dynamically optimize and adjust the film filling parameters corresponding to the abnormal areas based on the pressure difference. This reduces the probability of microcracks and cell breakage defects from the source, and improves the stability of the lamination process and the product yield.

[0015] Other features and advantages of the invention will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention are realized and obtained through the structures particularly pointed out in the description and the drawings.

[0016] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0017] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0018] Figure 1 A flowchart of a photovoltaic module lamination process provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the structure of a thin-film pressure sensor and a cell array in a photovoltaic module lamination process provided by an embodiment of the present invention. Figure 3A schematic diagram of the structure of a thin-film pressure sensor, a cell array, and a back glass opening in a photovoltaic module lamination process provided in an embodiment of the present invention; Figure 4 A curve showing the percentage of pressure difference between adjacent regions before optimization of back glass opening in a photovoltaic module lamination process provided in this embodiment of the invention; Figure 5 A curve showing the percentage of pressure difference between adjacent regions after optimization of back glass opening in a photovoltaic module lamination method provided in this embodiment of the invention; Figure 6 This is a schematic diagram of a photovoltaic module lamination system provided in an embodiment of the present invention; Figure 7 This is a schematic diagram of the structure of an electronic device provided in an embodiment of the present invention.

[0019] icon: 100 - Initial Filling Processing Module; 200 - Pressure Difference Calculation Module; 300 - Strategy Update Processing Module; 400 - Lamination Update Processing Module; 101 - Processor; 102 - Memory; 103 - Bus; 104 - Communication interface. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] To facilitate understanding of this embodiment, a photovoltaic module lamination method disclosed in this embodiment will first be described, as follows: Figure 1 As shown, it includes: Step S101: Fill the encapsulant film into the cell array of the current photovoltaic module according to the target filling parameters.

[0022] In the photovoltaic module stacking process, the cell strings are first arranged and positioned to form a cell array composed of multiple cells. Then, according to preset target filling parameters, photovoltaic encapsulating film is laid in the corresponding areas of the cell array to complete the encapsulation film filling operation. Simultaneously, thin-film pressure sensors are deployed to preset monitoring positions within the cell array. These preset monitoring positions include, but are not limited to, the cell string spacing area, the cell spacing area, and the area corresponding to the cells around the back glass openings. Each thin-film pressure sensor has multiple independent pressure detection points, each covering a different stress area on the cell surface, to achieve distributed in-situ monitoring of the cell's stress state.

[0023] Step S102: When laminating the current photovoltaic module, the pressure difference between adjacent pressure detection points is calculated in real time using the thin-film pressure sensor in the current photovoltaic module.

[0024] The photovoltaic modules, after being stacked and equipped with sensors, are fed into the lamination equipment to perform the lamination process. During the heating, pressurizing, and holding stages of the lamination process, thin-film pressure sensors embedded inside the modules synchronously collect real-time pressure data at each detection point, converting the stress changes on the cell surface into collectable electrical signals. Based on the real-time pressure data collected at each detection point, the pressure difference between two adjacent pressure detection points is continuously calculated, and the percentage of pressure difference between adjacent areas is further calculated to quantitatively characterize the uniformity of stress on the cell surface.

[0025] Step S103: When the pressure difference is detected to be greater than the preset difference threshold, the abnormal area of ​​the encapsulant film of the current photovoltaic module is obtained according to the pressure detection point corresponding to the pressure difference, and the filling and updating strategy of the abnormal area of ​​the encapsulant film is determined based on the pressure difference.

[0026] A preset safety threshold for the percentage of pressure difference between adjacent detection points is established. When the percentage of pressure difference between a group of adjacent detection points, calculated in real time, exceeds the preset threshold, it is determined that there is a risk of local stress concentration and uneven pressure at the location of the solar cell corresponding to that adjacent area, and this location is identified as an abnormal area of ​​the encapsulant film. Based on the pressure difference amplitude, stress distribution characteristics, and corresponding structural location of this abnormal area, a corresponding encapsulant film filling update strategy is generated. The update strategy includes, but is not limited to, increasing the encapsulant film filling amount in the abnormal area and pre-sealing the openings in the back glass to avoid encapsulant film leakage during lamination, so that the adjacent pressure difference in this area can fall back to the safe threshold range after parameter adjustment.

[0027] Step S104: Update the target filling parameters using the filling update strategy, fill the encapsulant film into the cell array of the next photovoltaic module according to the updated target filling parameters, and then perform lamination processing on the next photovoltaic module.

[0028] Based on the generated filling update strategy, parameters such as the amount of encapsulant and the laying process in the corresponding abnormal areas of the target filling parameters are directionally corrected to obtain optimized target filling parameters. In the subsequent production of photovoltaic modules in the same batch, the encapsulant filling operation is performed according to the updated target filling parameters, and then the lamination and stacking processes are completed sequentially. At the same time, pressure monitoring data of subsequent photovoltaic modules are continuously collected to verify the effect of parameter optimization. If there are still areas with uneven stress exceeding the threshold, the abnormal identification and parameter adjustment process is repeated to form a closed-loop optimization mechanism. This gradually controls the pressure difference between adjacent detection points on the surface of the cell within the safe threshold, reducing the incidence of microcracks and cell breakage caused by shear stress in the cells from the source, and improving the stability of the lamination process and the consistency of product yield.

[0029] Optionally, step S101, which involves filling the encapsulant film into the cell array of the current photovoltaic module according to the target filling parameters, includes the following steps: Step S201: Obtain the cell array, glass cover, and photovoltaic backsheet in the current photovoltaic module, and determine the target filling parameters of the encapsulant film based on the encapsulant film filling area between the glass cover and the photovoltaic backsheet.

[0030] Take the current photovoltaic module substrate to be processed and obtain the complete array of cells formed by multiple cells, the front glass cover, and the photovoltaic backsheet (back glass) with openings. Define the internal cavity formed by the glass cover and the photovoltaic backsheet as the encapsulant filling area. Based on the size of the filling area, the cell arrangement gap, the opening structure of the photovoltaic backsheet, and other structural features, calibrate the target encapsulant filling parameters suitable for this photovoltaic module.

[0031] Among them, the target filling parameters include benchmark process indicators such as the thickness of the encapsulant film in each zone, the standard filling amount, and the basic laying process specifications. These serve as benchmark filling standards that have not undergone stress optimization before the mass production of photovoltaic modules of the same model, replacing the traditional extensive mode that relies entirely on manual experience to set the amount of encapsulant film.

[0032] Step S202: Deploy the thin-film pressure sensor into the current photovoltaic module based on the film filling area, so that the pressure detection point of the thin-film pressure sensor covers at least the cell string spacing area, cell spacing area and opening area of ​​the photovoltaic backsheet of the cell array.

[0033] In the photovoltaic module stacking assembly process, based on the aforementioned defined adhesive film filling area, thin-film pressure sensors are mounted and deployed inside the current photovoltaic module. The sensor placement prioritizes covering the three core stress monitoring areas of the cell array: the string spacing area between cell strings, the cell spacing area within a single string, and the area corresponding to the cells around the openings in the photovoltaic backsheet. The sensor placement can be flexibly adjusted according to the module structure and is not limited to a single location. Specifically, as shown below... Figure 2 As shown.

[0034] A single thin-film pressure sensor is arranged along the edge of the solar cell and pre-divided into several independent pressure detection zones. Each detection point corresponds to a different stress position on the surface of the solar cell, realizing in-situ distributed monitoring of the stress on the solar cell throughout the lamination process. The thin-film pressure sensor is closely attached to the surface of the solar cell. During the lamination process, the forces generated by the melting of the adhesive film, the deformation of the glass, and the pressure of the silicone plate can be completely transmitted to the sensor and synchronously converted into collectable electrical signals. Moreover, the sensor layout does not interfere with the normal melting flow of the adhesive film and the module lamination process.

[0035] Step S203: Fill the adhesive film into the adhesive film filling area according to the target filling parameters.

[0036] Retrieve the target filling parameters obtained from step S201 calibration, and fill and lay the encapsulating film in all areas where the thin-film pressure sensors have been deployed, according to the film dosage, thickness, and laying method specified in the parameters. The filling operation must completely cover all sensor monitoring points, including gaps between battery strings, gaps between battery cells, and the area around the openings in the photovoltaic backsheet, to ensure uniform film filling in all areas under the baseline condition. After the film filling is completed, the glass cover, encapsulating film, battery cell array, and photovoltaic backsheet are stacked together to form a complete laminated component ready to be sent to the lamination equipment for subsequent lamination, pressurization, and pressure holding stress monitoring processes.

[0037] Optionally, step S102, which involves calculating the pressure difference between adjacent pressure detection points in real time using a thin-film pressure sensor in the current photovoltaic module during lamination, includes the following steps: Step S301: Based on the pressure detection points covered by the battery string spacing region, the battery cell spacing region, and the opening region, obtain the first pressure detection point set corresponding to the battery string spacing region, the second pressure detection point set corresponding to the battery cell spacing region, and the third pressure detection point set corresponding to the battery cell spacing region in the thin film pressure sensor.

[0038] Based on the initial deployment of thin-film pressure sensors, the sensor detection points fully cover three key areas prone to stress unevenness in lamination: the cell string spacing area, the cell spacing area, and the photovoltaic backsheet opening area. According to the component structure location corresponding to each detection point, they are grouped and categorized into three independent sets of detection points: all pressure detection points deployed in the cell string spacing area are grouped into the first pressure detection point set; all pressure detection points deployed in the cell spacing area are grouped into the second pressure detection point set; and all pressure detection points deployed at the cell locations corresponding to the openings in the photovoltaic backsheet are grouped into the third pressure detection point set.

[0039] Among them, a single thin-film pressure sensor is arranged along the edge of the battery cell and divided into multiple independent monitoring zones, such as Figure 3 As shown, there are 23 detection points. The risk points corresponding to the openings in the photovoltaic backsheet, such as Zones 4, 12, and 20, are uniformly included in the third pressure detection point set. By grouping the detection points by region, the stress data of different structural areas can be independently distinguished, avoiding mutual interference between pressure data at different locations, and facilitating subsequent accurate identification of stress anomalies by region.

[0040] Step S302: When it is detected that the current photovoltaic module is undergoing lamination processing, the pressure values ​​of each pressure detection point in the first pressure detection point set, the second pressure detection point set, and the third pressure detection point set are obtained in real time.

[0041] After the photovoltaic module lamination process is initiated, throughout the entire process of lamination heating, film melting and flow, overall pressurization of silicone plate, glass pressure equalization and deformation, and pressure holding and shaping, the thin film pressure sensor is continuously triggered to synchronously collect pressure data. After being subjected to the mechanical force of lamination, the thin film pressure sensor converts the actual pressure on the surface of the cell into a standardized electrical signal, and outputs the real-time pressure value of each independent pressure detection point in the first pressure detection point set, the second pressure detection point set, and the third pressure detection point set.

[0042] Data acquisition covers the entire lamination process without interruption, synchronously binds the location and zoning information corresponding to each pressure value, separately retains the pressure change curve of the photovoltaic backsheet opening area (third pressure detection point set), focuses on capturing the instantaneous pressure fluctuations of the points around the opening and the surrounding area, and completely retains the original in-situ stress data that can be traced.

[0043] Step S303: Determine the first pressure difference value corresponding to the battery string spacing area by using the pressure difference value between adjacent pressure detection points in the first pressure detection point set; determine the second pressure difference value corresponding to the battery cell spacing area by using the second pressure difference value between adjacent pressure detection points in the second pressure detection point set; and determine the third pressure difference value corresponding to the opening area by using the pressure difference value between adjacent pressure detection points in the third pressure detection point set.

[0044] Pressure difference calculations were performed on adjacent detection points within the three sets of detection points, and the stress difference index of the corresponding regions was obtained by partitioning the data. Traverse any two adjacent pressure detection points in the first pressure detection point set, calculate the real-time pressure difference between the two points, and define the difference as the first pressure difference value characterizing the uniformity of force on the gaps in the battery string. Traverse any two adjacent pressure detection points in the second pressure detection point set, calculate the real-time pressure difference between the two points, and define the difference as the second pressure difference value characterizing the uniformity of force between the gaps of a single string of battery cells. Traverse any two adjacent pressure detection points within the third pressure detection point set, calculate the real-time pressure difference between the two points, and define this difference as the third pressure difference value characterizing the uniformity of force around the opening of the photovoltaic backsheet.

[0045] Furthermore, the pressure difference between each region can be converted into the proportion of the pressure difference between adjacent regions as a quantitative evaluation standard. The backsheet opening area corresponding to this third pressure difference is a high-incidence area of ​​lamination shear force. Low pressure at the opening will form significant shear stress with adjacent points, which is the core cause of microcracks and cell breakage in the battery cell. Calculating the pressure difference independently by region can accurately locate the structural type of the abnormality, providing zonal quantitative data support for subsequent targeted adjustments to the amount of encapsulant filling in the opening area, the gap between the series and cells, and the sealing process. Overall, the proportion of the pressure difference between adjacent points in all regions is controlled to be below the safe critical range of 5%.

[0046] Optionally, when a pressure difference is detected to be greater than a preset threshold, the abnormal area of ​​the encapsulant film of the photovoltaic module is obtained based on the pressure detection point corresponding to the pressure difference, including the following steps: Step S401: Obtain the first difference threshold, the second difference threshold, and the third difference threshold corresponding to the battery string spacing region, the battery cell spacing region, and the opening region; wherein, the first difference threshold is less than the second difference threshold, and the second difference threshold is less than the third difference threshold.

[0047] For three types of structural regions prone to uneven stress, corresponding differential pressure judgment thresholds are pre-matched: the first difference threshold for the battery string spacing region, the second difference threshold for the battery cell spacing region, and the third difference threshold for the photovoltaic backsheet opening region are obtained; the threshold values ​​are set to satisfy the gradient relationship: first difference threshold < second difference threshold < third difference threshold.

[0048] The technical basis for setting gradient thresholds is as follows: The risk of lamination failure varies significantly across different structural regions. The space between battery strings is open, providing ample space for the adhesive film to flow, making it easy to ensure uniform stress distribution; therefore, the most stringent pressure difference criterion is adopted. The gaps between battery cells are narrow, increasing the difficulty of adhesive film filling; therefore, the threshold is appropriately relaxed. The area with openings in the photovoltaic backsheet is the highest-risk area, where the adhesive film easily leaks and flows along the openings during lamination. The pressure at the opening points is significantly lower than the surrounding areas, easily leading to shear stress that can induce microcracks and cell breakage. Therefore, the third largest difference threshold among the three is set as the early warning standard. All thresholds are quantified using the proportion of pressure difference between adjacent detection points, and are all below the general safety threshold of 5%, achieving early warning of lamination anomalies.

[0049] Step S402: When the first pressure difference is detected to be greater than the first difference threshold, the first pressure test point corresponding to the first pressure difference in the first pressure detection point set is obtained, and the first abnormal area of ​​the adhesive film in the battery string spacing area is obtained through the first pressure test point.

[0050] The first pressure difference calculated in real time is compared with the preset first difference threshold. If the first pressure difference is determined to be greater than the first difference threshold, it means that there is a risk of uneven force in the battery string spacing area.

[0051] A set of adjacent points that generated the excessive pressure difference was retrieved and marked as the first pressure test point. Based on the spatial location of the component corresponding to the first pressure test point, the first abnormal area of ​​the encapsulant film within the battery string spacing area was accurately delineated. This abnormality is mostly caused by uneven thickness of the encapsulant film between strings or localized missing encapsulant film. Isolating this area allows for targeted adjustment of the inter-string reference encapsulant film filling amount, eliminating the potential for stress concentration between strings.

[0052] Step S403: When the second pressure difference is detected to be greater than the second difference threshold, the second pressure test point corresponding to the second pressure difference in the second pressure detection point set is obtained, and the second film abnormal area in the cell spacing area is obtained through the second pressure test point.

[0053] The second pressure difference is continuously compared with the second difference threshold. When the second pressure difference is detected to exceed the second difference threshold, the adjacent points of the second pressure detection points that exceed the standard pressure difference are extracted as the second pressure test points.

[0054] Based on the coordinates of the second pressure test point, the abnormal area of ​​the second adhesive film within the spacing between individual cells can be located. The narrow spacing between cells makes it easy for the adhesive film to accumulate locally or become insufficient after melting. Excessive pressure differential can cause excessive pressure on the edges of individual cells, resulting in microscopic hidden cracks. Identifying abnormal areas between cells allows for independent fine-tuning of the adhesive film placement parameters, preventing damage to the entire cell.

[0055] Step S404: When the detected third pressure difference is greater than the third difference threshold, obtain the third pressure test point corresponding to the third pressure difference in the third pressure detection point set, and obtain the third film abnormal area in the opening area through the third pressure test point.

[0056] The third pressure difference is compared with the third difference threshold with the largest value in real time. If the third pressure difference exceeds the third difference threshold, the adjacent points where the pressure difference exceeds the standard are captured as the third pressure test points. The abnormal area of ​​the third encapsulant film around the opening of the photovoltaic backsheet is locked in combination with the corresponding position of the test points.

[0057] Based on the actual test cases of this solution, the third pressure test point typically corresponds to high-risk locations such as zones 4, 12, and 20 of the back glass opening. During lamination in these opening areas, the encapsulant film is prone to leakage, and the pressure at this point is lower than that at surrounding test points, creating continuous shear force. This is the core cause of large-area microcracks and direct cell breakage in solar cells. After identifying the abnormal areas of the third encapsulant film, two targeted optimization methods can be adopted: increasing the total amount of encapsulant film filling around the opening and pre-sealing the back sheet opening to block the leakage path of the encapsulant film. This effectively reduces the pressure difference between the opening area and adjacent points, reducing the destructive effect of shear stress on the solar cell.

[0058] Optionally, determining the filling and renewal strategy for abnormal areas of the adhesive film based on the pressure difference includes the following steps: Step S501: Based on the first pressure difference, determine the first adhesive film filling amount of the first adhesive film abnormal area in the battery string spacing region.

[0059] The first pressure difference value corresponding to the excessive pressure difference in the battery string spacing area is extracted. The extent of the pressure difference exceeding the standard is used as the basis for quantitative adjustment, and a corresponding mapping relationship between the pressure difference value and the amount of adhesive film replenishment is established. The larger the pressure difference value, the more severe the local adhesive film deficiency and pressure imbalance in the battery string spacing. Based on the amount of the first pressure difference exceeding the standard, the amount of adhesive film to be replenished in the abnormal area of ​​the first adhesive film is calculated and added to the initial filling reference amount for that area to finally determine the first adhesive film filling amount suitable for the battery string spacing area.

[0060] With ample internal space between battery strings, excessive pressure differentials are often caused by insufficient thickness of local adhesive film. By adjusting the thickness of the adhesive film between strings according to the filling amount of the first adhesive film, the surface pressure caused by the pressure of the silicone plate and the deformation of the glass during the lamination stage can be balanced. This will control the pressure difference between adjacent detection points within the battery string spacing to within the safe critical range of 5%, eliminating the hidden danger of local stress concentration between strings.

[0061] Step S502: Based on the second pressure difference, determine the second adhesive film filling amount in the abnormal area of ​​the second adhesive film in the cell spacing region.

[0062] The second pressure difference value that exceeds the standard in the cell spacing area is retrieved. Based on the deviation of the pressure difference from the threshold, the amount of encapsulation film that needs to be added to the abnormal area of ​​the second encapsulation film is quantitatively calculated, and the amount of second encapsulation film filling suitable for the cell spacing area is determined.

[0063] With narrow gaps between solar cells, the molten adhesive film is prone to localized material shortages and accumulations during lamination. Excessive pressure differential can cause uneven pressure on the edges of the solar cells, inducing microscopic hidden cracks. Optimizing the inter-cell adhesive film laying specifications by using a matched second adhesive film filling amount can reduce the pressure difference between adjacent pressure detection points between cells, avoiding overload on the edges of individual solar cells and preventing defects.

[0064] Step S503: Based on the third pressure difference value, determine the third adhesive film filling amount and the opening degree value of the third adhesive film abnormal area in the opening area.

[0065] The perforated area of ​​the photovoltaic backsheet is a high-risk area for lamination shear stress, corresponding to the third pressure difference value, requiring simultaneous output of two types of adjustment parameters: Third film filling amount: Based on the extent of the third pressure difference exceeding the standard, calculate the total amount of additional film filling required in the abnormal area of ​​the third film around the opening of the back glass (typically corresponding to monitoring zones 4, 12, and 20) to make up for the material that leaks out of the film during the lamination and melting stage and alleviate the problem of low pressure at the opening point. Orifice opening value: The orifice opening control parameter is matched with the differential pressure amplitude. This opening value is used to guide the pre-sealing process of the back plate orifice opening, reduce the actual flow size of the orifice, and block the leakage channel of the molten adhesive film from the physical structure.

[0066] Step S504: Determine the filling and renewal strategy for each abnormal area of ​​the adhesive film by using the filling amount of the first adhesive film, the filling amount of the second adhesive film, the filling amount of the third adhesive film, and the opening size value.

[0067] By summarizing the first film filling amount, the second film filling amount, the third film filling amount, and the backsheet opening value obtained from the above calculations, each of the various correction parameters is bound to the corresponding three types of abnormal film areas: battery string spacing, battery cell spacing, and backsheet opening, forming a complete film filling and updating strategy that is independent in partition and coordinated in its operation.

[0068] The filling update strategy includes three layers of differentiated process parameters: the amount of adhesive film used for gaps between cell strings, the amount of adhesive film used for gaps between cells, and the amount of adhesive film used for the backsheet opening area plus the standard opening and sealing degree. When mass-producing photovoltaic modules, this filling update strategy can be directly used to globally correct the target filling parameters, obtain the optimized target filling parameters, and implement them in the production of the next module. This continuously controls the pressure difference between adjacent pressure detection points in all areas of the entire module within the 5% safety threshold, reducing cell microcracks and cell breakage caused by shear stress during the lamination process from the source, and improving the stability of the lamination process and the consistency of module products.

[0069] Optionally, the target fill parameters are updated using a fill update strategy, including the following steps: Step S601: When the pressure value of the pressure detection point at the opening area is less than the preset pressure threshold, the target film filling amount at the photovoltaic backsheet and the target opening degree value of the photovoltaic backsheet are determined based on the filling update strategy.

[0070] A baseline pressure threshold is pre-set for the photovoltaic backsheet opening area. This threshold is the lower limit of safe stress on the cell during the lamination and pressure holding stage. Real-time pressure values ​​of the third pressure detection point set (high-risk points such as zones 4, 12, and 20 around the back glass opening) are continuously collected throughout the lamination process. If the pressure value output by any pressure detection point corresponding to the opening is lower than the preset pressure threshold, it is determined that there is a problem of film leakage and insufficient local pressure in the opening area. Shear stress will be formed between the opening point and the surrounding area, which can easily cause microcracks and cell breakage.

[0071] At this point, the film filling update strategy generated in the previous steps is retrieved, and combined with the extent to which the third pressure difference value exceeds the standard for the opening area, two types of targeted optimization parameters are calculated simultaneously: the target film filling amount for the battery cell area around the opening, and the target opening value of the photovoltaic backsheet used to seal the leakage channel; the greater the pressure difference exceeds the standard, the more film filling amount is increased and the greater the opening opening shrinkage is, thus compensating for the lack of force in the opening area from both material supply and structural sealing dimensions.

[0072] Step S602: Calculate the film filling value of the opening area using the target film filling amount, and calculate the sealing target value of the opening area using the target opening size value.

[0073] Based on the optimized parameters output in step S601, two targeted updates are performed on the target fill parameters of the component production baseline: First, the film filling value of the opening area is calculated using the target film filling amount, and the original film filling value corresponding to the photovoltaic backsheet opening area in the target filling parameters is replaced. By increasing the total amount of encapsulation film laid around the opening, the material lost from the opening during the lamination heating and melting stage is compensated, and the basic pressure at the opening point is increased. Secondly, the target value for sealing the opening area is calculated using the target opening size value, which replaces the opening size value corresponding to the opening area sealing control parameter in the target filling parameter. Physical sealing is achieved by reducing the actual opening flow size of the back plate, thus blocking the path of molten adhesive film leakage to the outside from the source.

[0074] Step S603: Update the target filling parameters based on the film filling value and the sealing target value.

[0075] The film filling parameters and opening / sealing control parameters of the opening area updated in step S602 are integrated with the original benchmark filling parameters of the battery string spacing and cell spacing areas where no abnormalities have occurred, forming a complete set of new target filling parameters that are adapted to different areas.

[0076] The new target filling parameters include standardized process indicators for three regions: the amount of encapsulant used in the cell string spacing area, the amount of encapsulant used in the cell spacing area, and the specific encapsulant filling amount + opening and sealing standard for the photovoltaic backsheet opening area. These parameters serve as the standardized process basis for the production of the next batch of photovoltaic modules. After applying these parameters to complete the encapsulant filling, the pressure difference between adjacent pressure detection points in the entire module area can be stably controlled within a safe critical range of less than 5%, achieving pre-emptive prevention of abnormal lamination stress, reducing the incidence of cell microcracks and cell breakage defects from the source, and improving the process stability and product consistency of the module.

[0077] Optionally, after filling the encapsulant film into the cell array of the next photovoltaic module according to the updated target filling parameters, the next photovoltaic module is laminated, including the following steps: Step S701: Obtain the next photovoltaic module of the same model as the current photovoltaic module, and determine the target glass cover, target cell array and target photovoltaic backsheet that are stacked sequentially in the next photovoltaic module.

[0078] The next photovoltaic module with specifications that are completely consistent with the current photovoltaic module and have completed stress monitoring and parameter optimization is retrieved as the workpiece to be processed; the three core substrates of the next photovoltaic module are disassembled and determined to be stacked from top to bottom: target glass cover plate, target cell array formed by multiple cells arranged in a regular manner, and target photovoltaic back sheet (back glass) with process openings.

[0079] This type of photovoltaic backsheet with openings is a high-risk structure for lamination. During the lamination process, the molten adhesive film is prone to seeping outward from the opening location, causing insufficient local pressure on the cells around the opening and forming shear stress with the adjacent areas. This is the main cause of microcracks and cell breakage. Therefore, it is necessary to identify the opening structure of the backsheet in advance during the substrate identification stage to provide a structural basis for the optimization of the differential adhesive film filling in different areas.

[0080] Step S702: Obtain the target filling area of ​​the encapsulant film between the target glass cover and the target photovoltaic backsheet, and fill the encapsulant film into the target filling area using the updated target filling parameters.

[0081] The internal cavity formed by the target glass cover and the target photovoltaic backsheet is defined as the target filling area of ​​the encapsulant film. Based on the stress risk of the module, it is divided into three sub-areas: the cell string spacing filling area, the cell spacing filling area, and the filling area around the opening of the photovoltaic backsheet. The target filling parameters obtained through the aforementioned iterative update are retrieved, and the encapsulant film filling and laying operation is completed according to the process indicators matched to the sub-areas.

[0082] The target filling parameters at this stage include layered differential control indicators: the standard amount of adhesive film filling in the areas of battery string spacing and cell spacing, as well as the improved adhesive film filling amount and the target opening size sealing parameters after shrinkage, which are simultaneously optimized for the backsheet opening area. By increasing the total amount of adhesive film laid around the opening and reducing the flow size of the backsheet opening, the leakage path of the adhesive film is blocked, and the stress in the opening area is balanced from both material and structural dimensions. During the filling operation, thin-film pressure sensors are deployed in three key sub-areas. Each thin-film pressure sensor is arranged along the edge of the cell and divided into 23 independent pressure detection points to ensure that the surface pressure data of the cell can be collected in situ throughout the subsequent lamination process, so as to realize the verification of stress uniformity.

[0083] Step S703: After detecting that the encapsulant film in the next photovoltaic module has been filled, perform lamination processing on the next photovoltaic module.

[0084] After the encapsulant film is laid, the thin film pressure sensor is installed, and the substrates are stacked and assembled in all target filling areas of the next photovoltaic module, the complete stacked component is sent into the lamination equipment to start the entire lamination process.

[0085] The lamination process covers multiple stages, including heating and melting, overall pressurization of the silicone sheet, uniform pressure deformation of the glass cover, and constant temperature and pressure setting. Thin-film pressure sensors embedded within the module continuously output real-time pressure at each detection point, simultaneously calculating the percentage of pressure difference between adjacent points to verify the optimization effect of the target filling parameters. After parameter optimization using this solution, the percentage of pressure difference between adjacent areas in zones 4, 12, and 20 of the back glass opening can be controlled within a safe threshold of 5%, significantly reducing shear stress in the opening area and surrounding points, thus reducing microcracks and cell breakage defects from the source. If any points still exceed the pressure difference limit, the pressure difference identification and parameter update process is cyclically executed, forming a closed-loop process optimization mechanism of "monitoring-parameter adjustment-production-retesting," continuously improving the stability of the lamination process and the consistency of module products.

[0086] Optionally, after detecting that the encapsulant film in the next photovoltaic module has been completely filled and performing lamination on the next photovoltaic module, the method further includes the following steps: Step S801: Obtain the target pressure sensor in the next photovoltaic module, and use the target pressure sensor to obtain the first pressure value and the second pressure value between adjacent pressure detection points in the opening area; wherein, the target pressure sensor and the thin film pressure sensor have the same model and the same deployment location.

[0087] After the next photovoltaic module with the encapsulant film filled is sent into the lamination equipment and the lamination process is started, the target pressure sensor that has been pre-installed inside the next photovoltaic module is retrieved. The target pressure sensor uses the same hardware model as the thin film pressure sensor mentioned above, and the bonding and placement method of the sensor in the module stacking stage is consistent. It fully covers three types of high-risk stress areas: the spacing between cell strings, the spacing between cell cells, and the area around the back glass opening. Each sensor is divided into 23 independent pressure detection points, among which the back glass opening corresponds to areas 4, 12, and 20 as key monitoring points.

[0088] Throughout the entire process of lamination heating, film melting, silicone plate pressurization, and constant temperature and pressure holding, the target pressure sensor continuously converts the force on the surface of the solar cell into a standardized electrical signal output. Real-time pressure data corresponding to any set of adjacent pressure detection points within the opening area of ​​the photovoltaic backsheet are extracted separately, and the pressure at the two points is defined as the first pressure value and the second pressure value, respectively. This is specifically designed for fixed-point data collection in cases where openings are prone to leakage and pressure imbalance.

[0089] Step S802: Calculate the pressure difference between the first pressure value and the second pressure value, and obtain the minimum pressure value between the first pressure value and the second pressure value.

[0090] For the first pressure value and the second pressure value of the adjacent detection points in the opening area obtained in step S801, two basic numerical calculations are performed: First, calculate the absolute difference between the first pressure value and the second pressure value to obtain the pressure difference between the two points, which intuitively represents the force difference between the two points. Secondly, by comparing the values ​​of the first and second pressure values, the pressure with the smaller value is selected as the minimum pressure value.

[0091] Based on the actual test conditions of this solution, the molten adhesive film at the opening of the photovoltaic backsheet is prone to seeping outward along the opening. The pressure at the corresponding test point is generally lower than that at the surrounding adjacent points. Therefore, the minimum pressure value is usually the pressure at the opening point itself, which serves as the benchmark denominator for subsequent quantitative calculation of the degree of stress imbalance, thus eliminating the calculation deviation caused by the overall basic pressure fluctuation of the module.

[0092] Step S803: Determine the pressure difference between adjacent pressure detection points by the ratio of the pressure difference to the minimum pressure value.

[0093] Using the pressure difference obtained in step S802 as the numerator and the minimum pressure value as the denominator, calculate the ratio between the two and convert it into a percentage. Define the percentage result as the pressure difference between adjacent pressure detection points (i.e., the proportion of the pressure difference between adjacent areas in this scheme).

[0094] This quantitative indicator is the core evaluation criterion of this solution. Unlike simply using the absolute pressure difference to determine the uniformity of force, it can be adapted to different components and different lamination pressure benchmark conditions, and accurately reflects the degree of force imbalance between the opening point and the adjacent area. This solution sets a general safety standard of less than 5% of the pressure difference between adjacent points. If the percentage exceeds the standard, it means that there is significant shear stress between the two points, which can easily induce microcracks and cell breakage defects in the battery cell.

[0095] Step S804: When the pressure difference is greater than the preset difference threshold, update the filling update strategy based on the pressure difference, and update the target filling parameters using the filling update strategy.

[0096] A third difference threshold (the largest value among the three partition thresholds) is preset to adapt to the opening area of ​​the back panel. The pressure difference value of the opening area calculated in step S803 is compared with the preset difference threshold in real time. When the pressure difference value is greater than the preset difference threshold, it is determined that the current target filling parameters still cannot eliminate the problem of film leakage and pressure unevenness in the opening area, and the battery cell continues to be subjected to destructive shear force.

[0097] Based on the deviation of the excessive pressure difference, the amount of adhesive film required for the opening area and the corresponding backplate opening size and sealing parameters were recalculated, and a new filling and updating strategy was generated after iterative optimization. Then, the target filling parameters used in the current batch production were corrected a second time through the updated filling and updating strategy, and the amount of adhesive film filling around the opening was increased and the flow size of the backplate opening was reduced to block the adhesive film leakage channel.

[0098] Based on the measured data of this scheme, such as Figure 4 As shown, the pressure difference between adjacent areas in zones 4, 12, and 20 of the pre-existing back glass opening was as high as 3.99%, 4.79%, and 3.36%, respectively. After simultaneously increasing the amount of adhesive film filling around the opening and optimizing the opening size to complete the sealing, as shown... Figure 5 As shown, the pressure difference ratios in the three regions can be reduced to 1.79%, 1.94%, and 2.36%, respectively, which significantly weakens the shear force between the opening area and the surrounding points, thereby reducing the risk of microcracks and cell breakage during the lamination process.

[0099] As can be seen from the above photovoltaic module lamination method, this method embeds a thin-film pressure sensor inside the experimental photovoltaic module for in-situ monitoring. It uses the real-time collected pressure difference value to obtain the pressure distribution and stress change characteristics of the cells during the lamination process, accurately identifies abnormal areas such as local stress concentration, pressure unevenness, and exceeding the safety critical threshold, and can dynamically optimize and adjust the film filling parameters corresponding to the abnormal areas according to the pressure difference value. This reduces the probability of microcracks and cell breakage defects from the source, and improves the stability of the lamination process and the product yield.

[0100] Corresponding to the above embodiments of the photovoltaic module lamination method, this embodiment of the invention also provides a photovoltaic module lamination system, such as... Figure 6 As shown, the system includes: Initial filling processing module 100: used to fill the encapsulant film into the cell array of the current photovoltaic module according to the target filling parameters; Pressure difference calculation module 200: used to calculate the pressure difference between adjacent pressure detection points in real time using the thin film pressure sensor in the current photovoltaic module when laminating the current photovoltaic module; Strategy update processing module 300: When a pressure difference is detected to be greater than a preset difference threshold, it obtains the current abnormal area of ​​the encapsulant film of the photovoltaic module according to the pressure detection point corresponding to the pressure difference, and determines the filling update strategy of the abnormal area of ​​the encapsulant film based on the pressure difference. The lamination update processing module 400 is used to update the target filling parameters using a filling update strategy, fill the encapsulant film into the cell array of the next photovoltaic module according to the updated target filling parameters, and perform lamination processing on the next photovoltaic module.

[0101] As can be seen from the above photovoltaic module lamination system, the system embeds a thin-film pressure sensor inside the experimental photovoltaic module for in-situ monitoring. It uses the real-time collected pressure difference to obtain the pressure distribution and stress change characteristics of the cells during the lamination process, accurately identifies abnormal areas such as local stress concentration, uneven pressure, and exceeding the safety threshold, and can dynamically optimize and adjust the film filling parameters corresponding to the abnormal areas based on the pressure difference. This reduces the probability of microcracks and cell breakage defects from the source, and improves the stability of the lamination process and the product yield.

[0102] The photovoltaic module lamination system provided in this embodiment of the invention has the same implementation principle and technical effect as the aforementioned photovoltaic module lamination method embodiment. For the sake of brevity, any parts not mentioned in the system embodiment can be referred to the corresponding content in the aforementioned photovoltaic module lamination method embodiment.

[0103] This embodiment also provides an electronic device, the structural schematic diagram of which is shown below. Figure 7 As shown, the device includes a processor 101 and a memory 102; wherein, the memory 102 is used to store one or more computer instructions, which are executed by the processor to implement the steps of the photovoltaic module lamination process described above.

[0104] Figure 7 The electronic device shown also includes a bus 103 and a communication interface 104, with the processor 101, communication interface 104 and memory 102 connected via the bus 103.

[0105] The memory 102 may include high-speed random access memory (RAM) and may also include non-volatile memory, such as at least one disk storage device. The bus 103 may be an ISA bus, PCI bus, or EISA bus, etc. The bus can be divided into address bus, data bus, control bus, etc. For ease of representation, Figure 7 The symbol is represented by a single double-headed arrow, but this does not mean that there is only one bus or one type of bus.

[0106] The communication interface 104 is used to connect to at least one personnel terminal and other network units through a network interface, and to send encapsulated IPv4 packets or IPv4 packets to the personnel terminal through the network interface.

[0107] Processor 101 may be an integrated circuit chip with signal processing capabilities. In implementation, each step of the above method can be completed by the integrated logic circuitry in the hardware of processor 101 or by instructions in software form. The processor 101 can be a general-purpose processor, including a Central Processing Unit (CPU), a Network Processor (NP), etc.; it can also be a Digital Signal Processor (DSP), an Application Specific Integrated Circuit (ASIC), a Field-Programmable Gate Array (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, or discrete hardware components. It can implement or execute the methods, steps, and logic block diagrams disclosed in the embodiments of this disclosure. The general-purpose processor can be a microprocessor or any conventional processor. The steps of the methods disclosed in the embodiments of this disclosure can be directly manifested as execution by a hardware decoding processor, or execution by a combination of hardware and software modules in the decoding processor. The software module can reside in a mature storage medium in the art, such as random access memory, flash memory, read-only memory, programmable read-only memory, electrically erasable programmable memory, or registers. This storage medium is located in memory 102. The processor 101 reads the information in memory 102 and, in conjunction with its hardware, completes the steps of the method described in the foregoing embodiments.

[0108] This invention also provides a storage medium storing a computer program, which, when run by a processor, executes the steps of the photovoltaic module lamination method described in the foregoing embodiments.

[0109] In the several embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, devices, and methods can be implemented in other ways. The system embodiments described above are merely illustrative. For example, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. Furthermore, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Additionally, the coupling or direct coupling or communication connection shown or discussed may be through some communication interfaces; the indirect coupling or communication connection between devices or units may be electrical, mechanical, or other forms.

[0110] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0111] In addition, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit.

[0112] If the aforementioned functions are implemented as software functional units and sold or used as independent products, they can be stored in a processor-executable, non-volatile, computer-readable storage medium. Based on this understanding, the technical solution of this invention, essentially, or the part that contributes to the prior art, or a portion of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, electronic device, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0113] Finally, it should be noted that the above-described embodiments are merely specific implementations of the present invention, used to illustrate the technical solutions of the present invention, and not to limit it. The scope of protection of the present invention is not limited thereto. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that any person skilled in the art can still modify or easily conceive of changes to the technical solutions described in the foregoing embodiments within the technical scope disclosed in the present invention, or make equivalent substitutions for some of the technical features; and these modifications, changes, or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be covered within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A method for laminating photovoltaic modules, characterized in that, The method includes: The encapsulant film is filled into the cell array of the current photovoltaic module according to the target filling parameters; During the lamination process of the current photovoltaic module, the pressure difference between adjacent pressure detection points is calculated in real time using the thin-film pressure sensor in the current photovoltaic module. When the pressure difference is detected to be greater than a preset difference threshold, the abnormal area of ​​the encapsulant film of the current photovoltaic module is obtained according to the pressure detection point corresponding to the pressure difference, and the filling and updating strategy of the abnormal area of ​​the encapsulant film is determined based on the pressure difference. The target filling parameters are updated using the filling update strategy. After the encapsulant film is filled into the cell array of the next photovoltaic module according to the updated target filling parameters, the next photovoltaic module is laminated.

2. The photovoltaic module lamination method according to claim 1, characterized in that, The steps of filling the encapsulant film into the cell array of the current photovoltaic module according to the target filling parameters include: Obtain the cell array, glass cover, and photovoltaic backsheet in the current photovoltaic module, and determine the target filling parameters of the encapsulant film based on the encapsulant film filling area between the glass cover and the photovoltaic backsheet; The thin-film pressure sensor is deployed in the current photovoltaic module based on the film filling area, such that the pressure detection point of the thin-film pressure sensor covers at least the cell string spacing area, the cell spacing area and the opening area of ​​the photovoltaic backsheet of the cell array. The adhesive film is filled into the adhesive film filling area according to the target filling parameters.

3. The photovoltaic module lamination method according to claim 2, characterized in that, The step of calculating the pressure difference between adjacent pressure detection points in real time using a thin-film pressure sensor in the current photovoltaic module during lamination includes: Based on the pressure detection points covered by the battery string spacing region, the battery cell spacing region, and the opening region, the first pressure detection point set corresponding to the battery string spacing region, the second pressure detection point set corresponding to the battery cell spacing region, and the third pressure detection point set corresponding to the battery cell spacing region in the thin film pressure sensor are obtained respectively. When lamination processing is detected in the current photovoltaic module, the pressure values ​​of each pressure detection point in the first pressure detection point set, the second pressure detection point set, and the third pressure detection point set are acquired in real time. The first pressure difference value corresponding to the battery string spacing area is determined by the pressure difference value between adjacent pressure detection points in the first pressure detection point set; the second pressure difference value corresponding to the battery cell spacing area is determined by the second pressure difference value between adjacent pressure detection points in the second pressure detection point set; and the third pressure difference value corresponding to the opening area is determined by the pressure difference value between adjacent pressure detection points in the third pressure detection point set.

4. The photovoltaic module lamination method according to claim 3, characterized in that, When the detected pressure difference value is greater than a preset difference threshold, the abnormal area of ​​the current photovoltaic module's encapsulant film is obtained based on the pressure detection point corresponding to the pressure difference value, including: Obtain a first difference threshold, a second difference threshold, and a third difference threshold corresponding to the battery string spacing region, the battery cell spacing region, and the opening region; wherein, the first difference threshold is less than the second difference threshold, and the second difference threshold is less than the third difference threshold; When the first pressure difference is detected to be greater than the first difference threshold, the first pressure test point corresponding to the first pressure difference in the first pressure detection point set is obtained, and the first abnormal area of ​​the adhesive film in the battery string spacing area is obtained through the first pressure test point. When the second pressure difference is detected to be greater than the second difference threshold, the second pressure test point corresponding to the second pressure difference in the second pressure detection point set is obtained, and the second abnormal area of ​​the adhesive film in the cell spacing area is obtained through the second pressure test point. When the third pressure difference is detected to be greater than the third difference threshold, the third pressure test point corresponding to the third pressure difference in the third pressure detection point set is obtained, and the third film abnormal area in the opening area is obtained through the third pressure test point.

5. The photovoltaic module lamination method according to claim 4, characterized in that, Determining the filling and renewal strategy for the abnormal areas of the adhesive film based on the pressure difference includes: Based on the first pressure difference, determine the first adhesive film filling amount of the first adhesive film abnormal area in the battery string spacing region; Based on the second pressure difference, determine the second adhesive film filling amount in the abnormal area of ​​the second adhesive film in the cell spacing region; Based on the third pressure difference value, determine the third adhesive film filling amount and the opening degree value of the third adhesive film abnormal area in the opening area; The filling and renewal strategy for each abnormal area of ​​the adhesive film is determined by the filling amount of the first adhesive film, the filling amount of the second adhesive film, the filling amount of the third adhesive film, and the aperture value.

6. The photovoltaic module lamination method according to claim 2, characterized in that, Updating the target fill parameters using the fill update strategy includes: When the pressure value at the pressure detection point in the opening area is less than the preset pressure threshold, the target film filling amount and the target opening degree of the photovoltaic backsheet are determined based on the filling update strategy. The film filling value of the opening area is calculated using the target film filling amount, and the sealing target value of the opening area is calculated using the target opening size value; The target filling parameters are updated based on the film filling value and the sealing target value.

7. The photovoltaic module lamination method according to claim 1, characterized in that, After filling the encapsulant film into the cell array of the next photovoltaic module according to the updated target filling parameters, the next photovoltaic module is laminated, including: Obtain the next photovoltaic module of the same model as the current photovoltaic module, and determine the target glass cover, target cell array and target photovoltaic backsheet that are stacked sequentially in the next photovoltaic module; Obtain the target filling area of ​​the adhesive film between the target glass cover and the target photovoltaic backsheet, and fill the adhesive film into the target filling area using the updated target filling parameters; After detecting that the encapsulant film in the next photovoltaic module has been completely filled, a lamination process is performed on the next photovoltaic module.

8. The photovoltaic module lamination method according to claim 7, characterized in that, After detecting that the encapsulant film in the next photovoltaic module has been completely filled, and following the step of performing lamination on the next photovoltaic module, the method further includes: The target pressure sensor in the next photovoltaic module is obtained, and the first pressure value and the second pressure value between adjacent pressure detection points at the opening area are obtained using the target pressure sensor; wherein the target pressure sensor is the same model and the same deployment location as the thin film pressure sensor; Calculate the pressure difference between the first pressure value and the second pressure value, and obtain the minimum pressure value between the first pressure value and the second pressure value; The pressure difference between adjacent pressure detection points is determined by the ratio of the pressure difference to the minimum pressure value. When the pressure difference is greater than a preset difference threshold, the filling update strategy is updated based on the pressure difference, and the target filling parameters are updated using the filling update strategy.

9. A photovoltaic module lamination system, characterized in that, The system includes: Initial filling processing module: used to fill the encapsulant film into the cell array of the current photovoltaic module according to the target filling parameters; Pressure difference calculation module: used to calculate the pressure difference between adjacent pressure detection points in real time using the thin film pressure sensor in the current photovoltaic module when laminating the current photovoltaic module; Strategy update processing module: When the pressure difference is detected to be greater than a preset difference threshold, the module obtains the abnormal area of ​​the encapsulant film of the current photovoltaic module according to the pressure detection point corresponding to the pressure difference, and determines the filling update strategy of the abnormal area of ​​the encapsulant film based on the pressure difference. The lamination update processing module is used to update the target filling parameters using the filling update strategy, fill the encapsulant film into the cell array of the next photovoltaic module according to the updated target filling parameters, and then perform lamination processing on the next photovoltaic module.

10. An electronic device, characterized in that, The electronic device includes a processor and a memory, the memory storing computer-executable instructions that can be executed by the processor, the processor executing the computer-executable instructions to implement the steps of the photovoltaic module lamination method according to any one of claims 1 to 8.

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