Intelligent manufacturing control method of photovoltaic welding strip

Abstract

This invention discloses an intelligent manufacturing control method for photovoltaic (PV) solder ribbons. The method involves establishing a finite element model of a flattening die to simulate the flattening process of the PV solder ribbon. Based on the first-state data of the flattening process, the parameters of the flattening die are corrected. The flattening operation is simulated on the die, and the second-state data of the flattening operation is obtained to determine the desired force parameters corresponding to the flattening operation. Based on several PV solder ribbon specification parameters, stress generation during the flattening operation is predicted to obtain stress distribution data of the PV solder ribbon. The desired force parameters are then corrected, and a flattening process database is constructed. Based on real-time pressure state data and the flattening process database, the actual flattening operation is adjusted. By optimizing the flattening die parameters through finite element modeling, combining multi-point collaborative flattening operations with process database feedback adjustments, a balanced and stable pressure is applied to the PV solder ribbon, ensuring the consistency of the solder ribbon thickness.

Description

Technical Field

[0001] This invention relates to the field of welding processes, and in particular to an intelligent manufacturing control method for photovoltaic welding strips. Background Technology

[0002] In battery string welding scenarios, as the spacing between solar cells gradually decreases from the conventional 1.8mm to 0.5mm, or even negative spacing (such as 0.4mm), the cells become increasingly thinner; some cells can be less than 130μm thick. At the junction of two cells, due to the small contact area between the cell and the solder ribbon, microcracks are easily caused during lamination. Existing solder ribbon flattening processes mainly rely on manual experience and simple mechanical equipment, resulting in problems such as high solder ribbon loss and poor product consistency. To increase the stress area between the solder ribbon and the solar cell and prevent microcracks, the solder ribbon needs to be flattened to optimize its contact performance with the solar cell by changing its shape. Existing photovoltaic solder ribbon flattening operations are usually performed using a single-point pressure mode, that is, applying pressure to a single point on the flattening die. This cannot create a balanced and stable pressure on the photovoltaic solder ribbon, nor can it provide timely and accurate feedback for adjustment and ensure the consistency of the solder ribbon thickness. Summary of the Invention

[0003] Considering that the existing photovoltaic ribbon flattening operation using a single-point pressure mode cannot provide timely and accurate feedback on the pressure application status and cannot form a balanced and stable pressure on the photovoltaic ribbon, it is impossible to ensure the consistency of the thickness of the flattened photovoltaic ribbon.

[0004] In view of the above problems, the present invention provides an intelligent manufacturing control method for photovoltaic ribbon, comprising: A finite element model of the flattening die is established to simulate the flattening process of the photovoltaic ribbon by the flattening die; the parameters of the flattening die are corrected based on the first state data of the flattening process. The flattening operation is simulated using the flattening mold, and the second state data of the flattening operation is obtained; based on the second state data, the desired force parameters corresponding to the flattening operation are determined. Based on several photovoltaic ribbon specifications, stress generation during the flattening process is predicted to obtain stress distribution data for the photovoltaic ribbon; based on the stress distribution data, the desired force parameters are corrected to construct a flattening process database. Real-time pressure status data of the actual flattening process is collected, and the flattening operation of the actual flattening process is adjusted based on the real-time pressure status data and the flattening process database; the execution status of the flattening operation is controlled based on the visual recognition results of the actual flattening process.

[0005] Optionally, a finite element model of the flattening die is established to simulate the flattening process of the photovoltaic ribbon by the flattening die, including: Several flattening molds were designed using computer-aided design; different flattening molds have different structural and dimensional data; based on the structural and dimensional data, finite element models of each flattening mold were established. Based on the finite element model, the dynamic flattening process of the photovoltaic solder strip by the flattening die is simulated, and the dynamic three-dimensional deformation data of the photovoltaic solder strip during the dynamic flattening process is generated, which is used as the first state data.

[0006] Optionally, the parameters of the flattening die are corrected based on the first state data of the flattening process, including: The dynamic three-dimensional deformation data were analyzed in both the time and spatial domains to obtain the deformation time variation curves of each grid cell within the photovoltaic ribbon. Based on the deformation time variation curve, identify abnormal mesh elements that do not meet the preset deformation conditions; Based on the spatial distribution and deformation deviation of the abnormal grid cells, the structural shape parameters of the flattening mold are corrected.

[0007] Optionally, a flattening operation simulation is performed on the flattening die, and second state data of the flattening operation is obtained, including: The flattening mold is subjected to a multi-point coordinated flattening operation simulation; wherein, the multi-point coordinated flattening operation refers to applying pressure to several points on the flattening mold respectively; The pressure magnitude and direction data applied at each point of action during the multi-point coordinated flattening operation, as well as the pressure distribution data of the photovoltaic ribbon, are obtained and used as the second state data.

[0008] Optionally, based on the second state data, the desired force parameters corresponding to the flattening operation are determined, including: Based on the position coordinates of all points of application, the magnitude and direction of the applied pressure, and the pressure distribution data, the correspondence between the applied pressure during the flattening operation and the pressure distribution formed by the photovoltaic ribbon is determined. Based on the correspondence and the expected pressure distribution of the photovoltaic ribbon, the expected force parameters corresponding to the flattening operation are determined; wherein, the expected force parameters include the expected pressure value and pressure direction to be applied to each point of action.

[0009] Optionally, based on several photovoltaic ribbon specification parameters, stress generation prediction is performed during the flattening process to obtain stress distribution data for the photovoltaic ribbon, including: Based on several photovoltaic ribbon specification parameters and the desired applied force parameters, stress generation simulation prediction is performed on the photovoltaic ribbon to obtain the internal stress distribution data of the photovoltaic ribbon; wherein, the several photovoltaic ribbon specification parameters include the size parameters and material composition parameters of the photovoltaic ribbon.

[0010] Optionally, based on the stress distribution data, the desired force application parameters are corrected to construct a flattening process database, including: Based on the internal stress distribution data, potential fracture areas are determined during the flattening operation of the photovoltaic ribbon; The desired force parameters are adjusted based on the distribution location and degree of fracture of the potential fracture zone. A flattening process database is constructed based on the aforementioned photovoltaic ribbon specifications and the corrected expected force parameters.

[0011] Optionally, real-time pressure status data during the actual flattening process can be collected, including: The actual pressure data received by the flattening mold during the actual flattening process is collected in real time and used as real-time pressure status data; wherein, the actual pressure data includes actual pressure magnitude data and actual pressure direction data.

[0012] Optionally, based on the real-time pressure status data and the flattening process database, the flattening operation of the actual flattening process is adjusted, including: By comparing the actual pressure data with the flattening process database, the deviations in pressure magnitude and direction are obtained. Based on the pressure magnitude deviation and the pressure direction deviation, a compensation control signal is generated and fed back to the pressure application mechanism to adjust the flattening operation of the pressure application mechanism in the actual flattening process.

[0013] Optionally, a compensation control signal is generated based on the pressure magnitude deviation and the pressure direction deviation, including: The number of action points n on the flattening mold is determined, and an initial coupling matrix C is established through offline finite element simulation or initial experimental calibration; wherein, the elements contained in the initial coupling matrix C are obtained by the following formula: ; Among them, C ij σ represents the element in the i-th row and j-th column of the initial coupling matrix; i p represents the actual pressure value corresponding to the i-th point of application; j δ represents the magnitude of the pressure applied at the j-th point of action; δ represents a preset small pressure disturbance. The angle between the actual pressure direction and the expected direction corresponding to each point of application is retrieved, and the amplification factor of the directional deviation for each point is obtained using the angle between the actual pressure direction and the expected direction. The amplification factor of the directional deviation corresponding to each point of action for compensation is obtained by the following formula: ; Among them, D j θ represents the amplification factor of the directional deviation corresponding to the j-th point of application for compensation. j θ represents the angle between the actual pressure direction and the desired direction at the j-th point of application; max This represents the maximum permissible directional deviation; λ represents the directional deviation sensitivity coefficient, with a value ranging from 0.3 to 0.5. The coefficient vector is obtained by using the amplification factor of the compensation based on the directional deviation corresponding to each point of application; Read the desired pressure vector and desired force parameters corresponding to the current photovoltaic ribbon specification from the flattening process database; The actual pressure values ​​collected by the pressure sensors at each point of application are retrieved to form a measured pressure vector. The required compensation pressure change is obtained by combining the measured pressure vector with a preset desired pressure vector, wherein the compensation pressure change is obtained by the following formula: ; Where ΔP represents the compensation pressure change; C represents the initial coupling matrix; σ des and σ act Let F represent the desired pressure vector and the measured pressure vector, respectively; α represents the nonlinear compensation coefficient, with a value of 0.3; F D This represents the L1 norm of the coefficient vector; A corresponding compensation control signal is generated based on the change in compensation pressure.

[0014] Optionally, based on the visual recognition results of the actual flattening process, the execution status of the flattening operation is controlled, including: Acquire images of the photovoltaic ribbon corresponding to the actual flattening process, and identify the shape change characteristics of the ribbon from the photovoltaic ribbon images; Based on the shape change characteristics of the solder strip, it is determined whether the photovoltaic solder strip has been flattened to the desired shape, thereby controlling the execution status of the flattening operation.

[0015] The beneficial effects of the above-mentioned technical solutions provided in the embodiments of the present invention include at least the following: This invention provides an intelligent manufacturing control method for photovoltaic (PV) solder ribbons. A finite element model of a flattening die is established to simulate the flattening process of the PV solder ribbon. Based on the first state data of the flattening process, the parameters of the flattening die are corrected. The flattening operation is simulated on the finite element model, and the second state data of the flattening operation is obtained. Based on the second state data, the desired force parameters corresponding to the flattening operation are determined. Based on several PV solder ribbon specification parameters, stress generation prediction during the flattening operation is performed to obtain stress distribution data of the PV solder ribbon. Based on the stress distribution data, the desired force parameters are corrected to construct a flattening process database. Real-time pressure state data of the actual flattening process is collected, and the flattening operation of the actual flattening process is adjusted based on the real-time pressure state data and the flattening process database. By optimizing the flattening die parameters through finite element modeling, combining multi-point collaborative flattening operations and process database feedback adjustments, a balanced and stable pressure is applied to the PV solder ribbon, ensuring the consistency of the solder ribbon thickness.

[0016] 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 may be realized and obtained by means of the structures particularly pointed out in the written description and the accompanying drawings.

[0017] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0018] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a flowchart illustrating an intelligent manufacturing control method for photovoltaic solder ribbon provided in an embodiment of the present invention.

[0019] Figure 2 It is the parameter correction process for the flattening mold.

[0020] Figure 3 This refers to the process of building a flattening process database.

[0021] Figure 4 It is the feedback adjustment process of the flattening operation. Detailed Implementation

[0022] Exemplary embodiments of the present disclosure will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

[0023] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," "outer," "far," "near," "front," and "rear," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0024] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0025] Please see Figure 1 As shown in the figure, an embodiment of this application provides a smart manufacturing control method for photovoltaic solder ribbon. The smart manufacturing control method for photovoltaic solder ribbon includes: A finite element model of the flattening die was established to simulate the flattening process of the photovoltaic ribbon; the parameters of the flattening die were corrected based on the first state data of the flattening process. The flattening operation of the flattening die is simulated, and the second state data of the flattening operation is obtained; based on the second state data, the expected force parameters corresponding to the flattening operation are determined. Based on several photovoltaic ribbon specifications, stress generation during the flattening process is predicted to obtain stress distribution data for the photovoltaic ribbon; based on the stress distribution data, the desired force parameters are corrected to construct a flattening process database. Collect real-time pressure status data during the actual flattening process, and adjust the flattening operation based on the real-time pressure status data and the flattening process database; control the execution status of the flattening operation based on the visual recognition results of the actual flattening process.

[0026] The beneficial effects of the above embodiments are that the intelligent manufacturing control method for photovoltaic ribbon optimizes the flattening mold parameters through finite element modeling, combines multi-point collaborative flattening operation and process database feedback adjustment, and forms a balanced and stable pressure on the photovoltaic ribbon to ensure the consistency of the ribbon thickness.

[0027] In another embodiment, a finite element model of the flattening die is established to simulate the flattening process of the photovoltaic ribbon by the flattening die, including: Several flattening molds were designed using computer-aided design; different flattening molds have different structural and dimensional data; based on the structural and dimensional data, finite element models of each flattening mold were established. Based on the finite element model, the dynamic flattening process of the photovoltaic solder strip by the flattening die is simulated, and the dynamic three-dimensional deformation data of the photovoltaic solder strip during the dynamic flattening process is generated, which is used as the first state data.

[0028] The photovoltaic (PV) ribbon flattening process involves placing the PV ribbon in a flattening die and applying pressure to the die using a pressure application mechanism. This flattening process uniformly flattens the PV ribbon to the required thickness. Different specifications and models of PV ribbon require different flattening dies, and these dies have different structures and dimensions. The flattening effect of the dies on the PV ribbon varies during the flattening process, resulting in different three-dimensional deformations (such as deformation in the thickness direction) of the PV ribbon throughout the process. Therefore, the structural dimensions of the flattening die directly affect the thickness flattening effect of the PV ribbon. Before implementing PV ribbon flattening, it is necessary to optimize the design of the flattening die. Computer-aided design software such as CAD can be used to design flattening dies with different structural and dimensional data. Finite element analysis software such as FEA can then be used to process this structural and dimensional data, establishing finite element models for each flattening die. These finite element models characterize the global structural features of each flattening die. The dynamic flattening process of the photovoltaic solder ribbon by the flattening die is then simulated using finite element analysis software. During the simulation, dynamic three-dimensional deformation data of the photovoltaic solder ribbon is generated, providing a reliable basis for subsequent correction of the die's structural shape parameters. This dynamic three-dimensional deformation data includes the deformation data of the flattening die's own three-dimensional structure during the dynamic flattening process. It is understood that this dynamic three-dimensional deformation data is directly related to the flattening operation applied by the flattening die. Through this analysis method, the structural parameters of the flattening die can be optimized, thereby improving the die's service life and flattening accuracy.

[0029] In another embodiment, the parameters of the flattening die are corrected based on the first state data of the flattening process, including: Temporal and spatial domain analyses were performed on the dynamic three-dimensional deformation data to obtain the deformation time variation curves of each grid element within the photovoltaic ribbon. Based on the deformation time variation curve, identify abnormal mesh elements that do not meet the preset deformation conditions; Based on the spatial distribution of abnormal grid cells and the amount of deformation deviation, the structural shape parameters of the flattening mold are corrected.

[0030] As discussed earlier, the flattening die applies pressure to the photovoltaic (PV) solder ribbon under the drive of a pressure application mechanism, thereby flattening the ribbon in terms of thickness. The structure of the flattening die itself affects the flattening effect on the PV solder ribbon. Ideally, if the structural shape parameters of the flattening die are compatible with the PV solder ribbon, the die can flatten the ribbon evenly; this even flattening means that the thickness reduction of each part of the PV solder ribbon is the same per unit time under the flattening action of the die. In reality, the structural shape parameters of the flattening die may not be perfectly compatible with the PV solder ribbon, preventing even flattening. For example, some parts of the PV solder ribbon may show a larger thickness reduction per unit time, while others may show a smaller reduction. To ensure even flattening of the PV solder ribbon by the flattening die, the structural shape parameters of the die need to be modified to fit the PV solder ribbon. Please refer to [link to relevant documentation]. Figure 2 The dynamic three-dimensional deformation data is analyzed in both the temporal and spatial domains to obtain the deformation time variation curves of each grid cell within the photovoltaic ribbon. These deformation time variation curves characterize the deformation (such as the amount of compression in the thickness direction) of each grid cell per unit time during the flattening process. Based on the deformation time variation curves, abnormal grid cells that do not meet the preset deformation conditions are identified. If the deformation of a grid cell per unit time during the flattening process is outside the preset deformation range, the grid cell is identified as an abnormal grid cell that does not meet the preset deformation conditions; otherwise, the grid cell is not identified as an abnormal grid cell that does not meet the preset deformation conditions. Then, based on the spatial distribution location and deformation deviation of the abnormal grid cells, the structural shape parameters of the flattening mold (such as the curvature of the flattening mold's structural contour) are corrected to ensure that the corrected structural shape parameters are perfectly matched with the photovoltaic ribbon.

[0031] In another embodiment, a flattening operation is simulated on the flattening die, and second state data of the flattening operation is obtained, including: Simulation of multi-point coordinated flattening operation on a flattening die; where multi-point coordinated flattening operation refers to applying pressure to several points on the flattening die respectively; Data on the magnitude and direction of pressure applied at each point of action during the multi-point coordinated flattening operation, as well as the pressure distribution data on the photovoltaic ribbon, are obtained and used as the second state data.

[0032] Whether photovoltaic (PV) ribbon can be uniformly flattened depends on the structural shape parameters of the flattening die and the pressure applied to the die by the pressure application mechanism during the flattening operation. It is understood that only when the pressure application mechanism applies pressure uniformly and synchronously to the flattening die can the PV ribbon be uniformly flattened, ensuring the consistency of the PV ribbon thickness. In actual operation, several points of application are uniformly selected on the flattening die, and pressure is applied to these points to achieve multi-point coordinated flattening operation. Data on the magnitude and direction of the pressure applied to each point during the multi-point coordinated flattening operation, as well as the pressure distribution data on the PV ribbon, are also obtained. This comprehensively characterizes the pressure condition on the flattening die and the pressure distribution on the PV ribbon itself, providing a reliable basis for subsequently determining the desired force parameters.

[0033] In another embodiment, determining the desired force parameters corresponding to the flattening operation based on the second state data includes: Based on the position coordinates of all points of application, the magnitude and direction of the applied pressure, and the pressure distribution data, the correspondence between the applied pressure during the flattening operation and the pressure distribution formed by the photovoltaic ribbon is determined. Based on the correspondence and the expected pressure distribution of the photovoltaic ribbon, the expected force parameters corresponding to the flattening operation are determined; among them, the expected force parameters include the expected pressure value and pressure direction to be applied to each point of action.

[0034] When the pressure application mechanism applies pressure to the flattening die, the photovoltaic ribbon placed on the die will be flattened and deformed accordingly. Therefore, based on the position coordinates of all points of application, the magnitude and direction of the applied pressure, and the pressure distribution data, the correspondence between the applied pressure during the flattening operation and the pressure distribution formed by the photovoltaic ribbon is determined. Then, based on this correspondence and the desired pressure distribution of the photovoltaic ribbon, the desired pressure value and direction applied to each point during the flattening operation are determined, providing a reference benchmark for subsequent multi-point coordinated flattening operations.

[0035] In another embodiment, stress generation during the flattening process is predicted based on several photovoltaic ribbon specification parameters to obtain stress distribution data for the photovoltaic ribbon, including: Based on several photovoltaic welding strip specification parameters and expected force parameters, stress generation simulation prediction is performed on the photovoltaic welding strip to obtain internal stress distribution data of the photovoltaic welding strip; among them, several photovoltaic welding strip specification parameters include the size parameters and material composition parameters of the photovoltaic welding strip.

[0036] When photovoltaic (PV) ribbons are flattened by a flattening die, their surface is compressed, leading to internal stress. The magnitude and direction of this internal stress are influenced by the ribbon's structural dimensions and material composition (e.g., the types and weight ratios of materials it contains). By performing stress generation simulations based on several PV ribbon specifications and desired force parameters, we can obtain internal stress distribution data for the PV ribbon, providing a basis for subsequently refining the desired force parameters.

[0037] In another embodiment, the desired force parameters are corrected based on stress distribution data to construct a flattening process database, including: Based on the internal stress distribution data, the potential fracture areas during the flattening operation of the photovoltaic welding strip were determined; The desired force parameters are adjusted based on the distribution and severity of potential fracture zones. A flattening process database was constructed based on several photovoltaic ribbon specifications and the revised expected force parameters.

[0038] Please see Figure 3 Based on internal stress distribution data, potential fracture zones are identified during the flattening process of photovoltaic (PV) ribbons. These potential fracture zones refer to areas where the internal stress in the PV ribbon is greater than or equal to the maximum internal stress limit that the ribbon material can withstand. Based on the distribution location and degree of fracture of these potential fracture zones, the desired force parameters are modified, such as reducing the pressure applied to the point closest to the potential fracture zone or changing the pressure direction. These PV ribbon specification parameters are then mapped and correlated with the modified desired force parameters to construct a flattening process database. It is understood that this flattening process database contains optimal multi-point pressure application schemes matching the corresponding PV ribbon specifications.

[0039] In another embodiment, real-time pressure status data of the actual flattening process is collected, including: The actual pressure data received by the flattening die during the actual flattening process is collected in real time and used as real-time pressure status data; the actual pressure data includes the actual pressure magnitude data and the actual pressure direction data.

[0040] In another embodiment, based on real-time pressure status data and a flattening process database, the flattening operation of the actual flattening process is adjusted, including: By comparing actual pressure data with the flattening process database, the deviations in pressure magnitude and direction are obtained. Based on the deviations in pressure magnitude and direction, a compensation control signal is generated and fed back to the pressure application mechanism to adjust the flattening operation of the pressure application mechanism during the actual flattening process.

[0041] In actual operation, the flattening die receives real-time data on the magnitude and direction of the applied pressure during the actual flattening process, enabling a comprehensive and accurate assessment of the stress state on the die. Please refer to [link / reference]. Figure 4 By comparing actual pressure data with the flattening process database, the deviations in pressure magnitude and direction are obtained. Compensation control signals are then generated and fed back to the pressure application mechanism to adjust the flattening operation of the pressure application mechanism during the actual flattening process, thereby achieving adaptive control of flattening of the photovoltaic ribbon.

[0042] In another embodiment, a compensation control signal is generated based on the pressure magnitude deviation and the pressure direction deviation, including: The number of action points n on the flattening mold is determined, and an initial coupling matrix C is established through offline finite element simulation or initial experimental calibration; wherein, the elements contained in the initial coupling matrix C are obtained by the following formula: ; Among them, C ij σ represents the element in the i-th row and j-th column of the initial coupling matrix; i p represents the actual pressure value corresponding to the i-th point of application; j δ represents the magnitude of the pressure applied at the j-th point of action; δ represents a preset small pressure disturbance. The angle between the actual pressure direction and the expected direction corresponding to each point of application is retrieved, and the amplification factor of the directional deviation for each point is obtained using the angle between the actual pressure direction and the expected direction. The amplification factor of the directional deviation corresponding to each point of action for compensation is obtained by the following formula: ; Among them, D j θ represents the amplification factor of the directional deviation corresponding to the j-th point of application for compensation. j θ represents the angle between the actual pressure direction and the desired direction at the j-th point of application; max This represents the maximum permissible directional deviation; λ represents the directional deviation sensitivity coefficient, with a value ranging from 0.3 to 0.5. The coefficient vector is obtained by using the amplification factor of the compensation based on the directional deviation corresponding to each point of application; Read the desired pressure vector and desired force parameters corresponding to the current photovoltaic ribbon specification from the flattening process database; The actual pressure values ​​collected by the pressure sensors at each point of application are retrieved to form a measured pressure vector. The required compensation pressure change is obtained by combining the measured pressure vector with a preset desired pressure vector, wherein the compensation pressure change is obtained by the following formula: ; Where ΔP represents the compensation pressure change; C represents the initial coupling matrix; σ des and σ act Let F represent the desired pressure vector and the measured pressure vector, respectively; α represents the nonlinear compensation coefficient, with a value of 0.3; F D This represents the L1 norm of the coefficient vector; A corresponding compensation control signal is generated based on the change in compensation pressure.

[0043] By rationally setting the directional deviation amplification factor, the compensation intensity can be dynamically adjusted according to the degree of deviation in the pressure direction at each point of application. This avoids uneven local stress caused by directional deviation, reduces defects such as skewing and uneven thickness of the weld strip, ensures consistent weld strip formation, effectively avoids secondary deviations caused by single compensation, and significantly improves the weld strip forming accuracy, far exceeding the effect of conventional compensation schemes. Furthermore, the compensation lag time is significantly shortened, and it remains stable even at critical parameter values, avoiding control failures caused by parameter anomalies and significantly improving process stability. Simultaneously, it achieves precise calculation of the compensation amount, taking into account both nonlinear correction of pressure deviation and targeted compensation for directional deviation, effectively improving the response speed and control accuracy of compensation control. Moreover, the above technical solution can adapt to the flattening requirements of photovoltaic weld strips of different specifications. By retrieving parameters from the process database, adaptive adjustment of compensation control is achieved, reducing manual debugging costs and improving production efficiency. It also avoids control failures caused by parameter singularities, enhances the stability and reliability of process operation, reduces product scrap due to pressure deviation, and ensures the mechanical and electrical properties of the photovoltaic weld strip.

[0044] In another embodiment, controlling the execution of the flattening operation based on the visual recognition results of the actual flattening process includes: Acquire images of photovoltaic ribbons corresponding to the actual flattening process, and identify the shape change characteristics of the ribbons from the photovoltaic ribbon images; Based on the shape change characteristics of the solder ribbon, it is determined whether the photovoltaic solder ribbon has been flattened to the desired shape, thereby controlling the execution status of the flattening operation.

[0045] In actual operation, the photovoltaic ribbon image corresponding to the actual flattening process is obtained, and the shape change characteristics of the photovoltaic ribbon are identified from the photovoltaic ribbon image, such as the actual thickness compression amount of the photovoltaic ribbon per unit time. If the actual thickness compression amount is greater than or equal to the preset compression amount threshold, it is determined that the photovoltaic ribbon has been flattened to the desired shape, and the flattening operation is stopped at this time; otherwise, it is determined that the photovoltaic ribbon has not been flattened to the desired shape, and the flattening operation continues.

[0046] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. This disclosure is not limited to the precise structures described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of this disclosure is limited only by the appended claims. Thus, if these modifications and variations of the invention fall within the scope of the claims of the invention and their equivalents, the invention is also intended to include these modifications and variations.

Claims

1. A smart manufacturing control method for photovoltaic welding strips, characterized in that, include: A finite element model of the flattening die was established to simulate the flattening process of the photovoltaic ribbon by the flattening die. Based on the first state data of the flattening process, the parameters of the flattening mold are corrected; The flattening operation of the flattening mold is simulated, and the second state data of the flattening operation is obtained; Based on the second state data, determine the desired force parameters corresponding to the flattening operation; Based on several photovoltaic ribbon specifications, stress generation during the flattening process is predicted to obtain stress distribution data for the photovoltaic ribbon. Based on the stress distribution data, the desired force application parameters are corrected to construct a flattening process database. Real-time pressure status data of the actual flattening process is collected, and the flattening operation of the actual flattening process is adjusted based on the real-time pressure status data and the flattening process database; the execution status of the flattening operation is controlled based on the visual recognition results of the actual flattening process.

2. The intelligent manufacturing control method for photovoltaic welding strips as described in claim 1, characterized in that: A finite element model of the flattening die is established to simulate the flattening process of the photovoltaic ribbon by the flattening die, including: Several flattening molds were designed using computer-aided design; different flattening molds have different structural and dimensional data; based on the structural and dimensional data, finite element models of each flattening mold were established. Based on the finite element model, the dynamic flattening process of the photovoltaic solder strip by the flattening die is simulated, and the dynamic three-dimensional deformation data of the photovoltaic solder strip during the dynamic flattening process is generated, which is used as the first state data.

3. The intelligent manufacturing control method for photovoltaic welding strips as described in claim 2, characterized in that: Based on the first state data of the flattening process, the parameters of the flattening die are corrected, including: The dynamic three-dimensional deformation data were analyzed in both the time and spatial domains to obtain the deformation time variation curves of each grid cell within the photovoltaic ribbon. Based on the deformation time variation curve, identify abnormal mesh elements that do not meet the preset deformation conditions; Based on the spatial distribution and deformation deviation of the abnormal grid cells, the structural shape parameters of the flattening mold are corrected.

4. The intelligent manufacturing control method for photovoltaic welding strips as described in claim 1, characterized in that: The flattening operation of the flattening mold is simulated, and the second state data of the flattening operation is obtained, including: The flattening mold is subjected to a multi-point coordinated flattening operation simulation; wherein, the multi-point coordinated flattening operation refers to applying pressure to several points on the flattening mold respectively; The pressure magnitude and direction data applied at each point of action during the multi-point coordinated flattening operation, as well as the pressure distribution data of the photovoltaic ribbon, are obtained and used as the second state data.

5. The intelligent manufacturing control method for photovoltaic welding strips as described in claim 4, characterized in that: Based on the second state data, the desired force parameters corresponding to the flattening operation are determined, including: Based on the position coordinates of all points of application, the magnitude and direction of the applied pressure, and the pressure distribution data, the correspondence between the applied pressure during the flattening operation and the pressure distribution formed by the photovoltaic ribbon is determined. Based on the correspondence and the expected pressure distribution of the photovoltaic ribbon, the expected force parameters corresponding to the flattening operation are determined; wherein, the expected force parameters include the expected pressure value and pressure direction to be applied to each point of action.

6. The intelligent manufacturing control method for photovoltaic welding strips as described in claim 1, characterized in that: Based on several photovoltaic ribbon specifications, stress generation during the flattening process is predicted to obtain stress distribution data for the photovoltaic ribbon, including: Based on several photovoltaic ribbon specification parameters and the desired applied force parameters, stress generation simulation prediction is performed on the photovoltaic ribbon to obtain the internal stress distribution data of the photovoltaic ribbon; wherein, the several photovoltaic ribbon specification parameters include the size parameters and material composition parameters of the photovoltaic ribbon.

7. The intelligent manufacturing control method for photovoltaic welding strips as described in claim 6, characterized in that: Based on the stress distribution data, the desired force parameters are corrected to construct a flattening process database, including: Based on the internal stress distribution data, potential fracture areas are determined during the flattening operation of the photovoltaic ribbon; The desired force parameters are adjusted based on the distribution location and degree of fracture of the potential fracture zone. A flattening process database is constructed based on the aforementioned photovoltaic ribbon specifications and the corrected expected force parameters.

8. The intelligent manufacturing control method for photovoltaic welding strips as described in claim 1, characterized in that: Collect real-time pressure data during the actual flattening process, including: The actual pressure data received by the flattening mold during the actual flattening process is collected in real time and used as real-time pressure status data; wherein, the actual pressure data includes actual pressure magnitude data and actual pressure direction data.

9. The intelligent manufacturing control method for photovoltaic welding strips as described in claim 1, characterized in that: Based on the real-time pressure status data and the flattening process database, the flattening operation of the actual flattening process is adjusted, including: By comparing the actual pressure data with the flattening process database, the deviations in pressure magnitude and direction are obtained. Based on the pressure magnitude deviation and the pressure direction deviation, a compensation control signal is generated and fed back to the pressure application mechanism to adjust the flattening operation of the pressure application mechanism in the actual flattening process.

10. The intelligent manufacturing control method for photovoltaic welding strips as described in claim 1, characterized in that: Based on the pressure magnitude deviation and the pressure direction deviation, a compensation control signal is generated, including: The number of action points n on the flattening mold is determined, and an initial coupling matrix C is established through offline finite element simulation or initial experimental calibration; wherein, the elements contained in the initial coupling matrix C are obtained by the following formula: ； Among them, C ij σ represents the element in the i-th row and j-th column of the initial coupling matrix; i p represents the actual pressure value corresponding to the i-th point of application; j δ represents the magnitude of the pressure applied at the j-th point of action; δ represents a preset small pressure disturbance. The angle between the actual pressure direction and the expected direction corresponding to each point of application is retrieved, and the amplification factor of the directional deviation for each point is obtained using the angle between the actual pressure direction and the expected direction. The amplification factor of the directional deviation corresponding to each point of action for compensation is obtained by the following formula: ； Among them, D j θ represents the amplification factor of the directional deviation corresponding to the j-th point of application for compensation. j θ represents the angle between the actual pressure direction and the desired direction at the j-th point of application; max This represents the maximum permissible directional deviation; λ represents the directional deviation sensitivity coefficient, with a value ranging from 0.3 to 0.

5. The coefficient vector is obtained by using the amplification factor of the compensation based on the directional deviation corresponding to each point of application; Read the desired pressure vector and desired force parameters corresponding to the current photovoltaic ribbon specification from the flattening process database; The actual pressure values ​​collected by the pressure sensors at each point of application are retrieved to form a measured pressure vector. The required compensation pressure change is obtained by combining the measured pressure vector with a preset desired pressure vector, wherein the compensation pressure change is obtained by the following formula: ； Where ΔP represents the compensation pressure change; C represents the initial coupling matrix; σ des and σ act Let F represent the desired pressure vector and the measured pressure vector, respectively; α represents the nonlinear compensation coefficient, with a value of 0.3; F D This represents the L1 norm of the coefficient vector; A corresponding compensation control signal is generated based on the change in compensation pressure.

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