Photovoltaic adhesive film intelligent casting line

Abstract

The present application relates to photovoltaic adhesive film production technology field, specifically to a kind of photovoltaic adhesive film intelligent flow line, including several active traction roller, extrusion die head from front to back sequentially linked, mesh belt machine, three-roller embossing unit, transition zone, slitting machine and ≥2 groups of winding machine;Three-roller embossing unit is provided with cooling mechanism and thickness measuring mechanism between transition zone, cooling mechanism includes the cooling roller group one and the cooling roller group two arranged in front and back, and the thickness measuring mechanism is clamped between the cooling roller group one and the cooling roller group two;Transition zone is provided with double-layer mesh belt section and track section from top to bottom, and the track section includes the track one and the track two arranged in front and back, and the rear end of the track two is connected with slitting machine, and the line uses transverse three-section type temperature control;Photovoltaic adhesive film is automatically matched with roller speed in the process of extrusion to winding, matched with multistage cooling device, makes photovoltaic adhesive film tension uniform, reaches constant tension transmission, introduces floating roller tension system, adjusts the roller speed of each active roller, realizes automatic closed-loop control.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic encapsulant film production technology, specifically to an intelligent photovoltaic encapsulant film casting line. Background Technology

[0002] Currently, photovoltaic encapsulant film is a key auxiliary material for photovoltaic module encapsulation. Although it accounts for a small percentage of the absolute cost of the module (approximately 5% to 7%), its performance and stability have a significant impact on the power generation efficiency and lifespan of the photovoltaic module. Photovoltaic modules have a lifespan of 25 to 40 years in photovoltaic power plants. If problems such as yellowing, delamination, or water permeation occur during this period, or if PID (Potential Influence of Degradation) effects develop, it will lead to reduced cell efficiency or even failure, directly affecting power generation and the operating revenue of the power plant.

[0003] After the photovoltaic encapsulant film is extruded and embossed, successful winding requires a series of processes including cooling and tension release. However, unlike rigid plastic products, photovoltaic encapsulant film possesses a certain degree of elasticity, and winding it requires a certain amount of stretching. The uncontrollable tension of the photovoltaic encapsulant film easily leads to problems such as insufficient shrinkage, uneven winding, and wrinkling. Current technology relies excessively on experienced employees manually adjusting the speed of each cooling roller on the film casting line to ensure the film reaches the required tension range. However, the uncertainty of human operation is too great, and there are too many uncontrollable factors, which limits the improvement of photovoltaic encapsulant film production quality, thus reducing production speed and resulting in lost capacity. Summary of the Invention

[0004] The purpose of this invention is to provide an automatic and intelligent solution for matching roller speed and film temperature during the extrusion and embossing process of the film and the winding process, which can effectively improve the quality of the film and reduce the risk of loss due to human operation.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A photovoltaic encapsulant film intelligent casting line includes several active traction rollers, an extrusion die head connected from front to back, a mesh belt machine, a three-roll embossing machine unit, a transition zone, a slitting machine, and ≥2 sets of winding machines; A cooling mechanism and a thickness measuring mechanism are provided between the three-roll embossing machine unit and the transition zone. The cooling mechanism includes a cooling roller group one and a cooling roller group two arranged in front and behind. The thickness measuring mechanism is a thickness gauge, which is sandwiched between the cooling roller group one and the cooling roller group two. The photovoltaic film passes laterally through the thickness gauge. The transition zone is provided with a double-layer mesh belt section and a track section from top to bottom. The double-layer mesh belt section includes upper and lower double-layer parallel PTFE woven conveyor mesh belts with the following parameters: mesh size: 3mm×5mm, tension independently adjustable (0~15N, adjustment step 0.1N), running speed adjustable from 0~45m / min, and equipped with a correction device with a correction response time ≤35ms and repeatability accuracy ±0.05mm. The front-to-back length of the track section is greater than that of the double-layer mesh belt section. The track section includes track one and track two connected front to back, and the rear end of track two is connected to a slitting machine. The casting line adopts a horizontal three-section independent temperature control design. The first section maintains 25±2℃ to stabilize the surface state of the photovoltaic film. The second section gradually cools down to 23±1.5℃ to suppress the release of residual stress in the photovoltaic film. The third section maintains a constant temperature of 20±1℃ to complete the final shaping of the photovoltaic film. The temperature control response time of each section is ≤8 seconds, and the temperature uniformity is ≤±0.5℃. The casting line is equipped with several active traction rollers, each equipped with a servo motor (rated torque ≥12N·m, dynamic response bandwidth ≥20Hz) and a high linearity photoelectric encoder (pulse resolution ≥50ppr). Together with the edge computing unit, it achieves millisecond-level synchronous adjustment of roller speed (command delay ≤2ms, position synchronization error ≤±0.01mm). The servo driver has a built-in PID parameter self-tuning function, supports tension feedforward compensation and speed loop cross-coupling control, and ensures the consistency of multi-roller coordinated response. The slitting machine includes a cutting roller, which cuts a single row of wide photovoltaic film into multiple rows of narrow photovoltaic film, with each row of narrow photovoltaic film connected to a winding machine. It also includes a floating tension detection mechanism, which is located between the first cooling roller group and the thickness gauge, between the second cooling roller group and the double-layer mesh belt section (upper layer), between the second track and the slitting machine, and between the slitting machine and the winding machine. The floating tension detection mechanism includes: The first and second swing arms are fixedly connected to form a crank lever structure, with a swing shaft in the middle forming a fulcrum for rotation. A floating roller, which is rotatably connected to an end of the swing arm away from the pivot point; A weight is connected to the end of the second swing arm away from the pivot point. The weight provides a constant tension force to the floating roller through the lever torque, which is the core of the tension setting. The set tension value of the system can be adjusted by changing the weight of the weight. The swing shaft is coaxially connected to a strain gauge tension sensor and an angle encoding mechanism, which can detect the deflection angle of the crank lever structure in real time without gaps, indirectly reflecting the real-time tension of the photovoltaic film, and output analog / digital signals to the back-end control system. On the film-carrying path of the photovoltaic film, fixed guide rollers are provided before and after the floating roller. The fixed guide rollers are in a fixed position and are used to constrain the film-carrying path of the photovoltaic film and provide a stable wrap angle for the floating roller. The floating roller swings synchronously with the crank lever structure and directly contacts the photovoltaic film, serving as a direct tension action and detection carrier.

[0006] The floating tension detection mechanism between the second cooling roller assembly and the double-layer mesh belt section is equipped with a dynamic eccentricity compensation module.

[0007] Furthermore, the three-roll embossing unit includes an embossing roller and a matching extrusion roller arranged close together, with a photovoltaic film passing through between them; it also includes a cold roller arranged away from the mesh belt machine, with the embossing roller disposed between the matching extrusion roller and the cold roller.

[0008] Furthermore, the first cooling roller assembly includes a second cooling roller, a third cooling roller, and a fourth cooling roller arranged in parallel in sequence, with the third cooling roller being arranged at a higher height than the second and fourth cooling rollers. The photovoltaic film is fed sequentially from below the second cold roller, above the third cold roller, and below the fourth cold roller.

[0009] Furthermore, the second cooling roller assembly includes a fifth and a sixth cooling roller arranged in parallel in sequence, wherein the height of the sixth cooling roller is higher than that of the fifth cooling roller. The photovoltaic film is fed sequentially from below the fifth cold roller and above the sixth cold roller.

[0010] Furthermore, the track section includes track one and track two connected front to back and arranged at the same height. The front end of track one is connected to a double-layer mesh belt section, which transports photovoltaic film from above to track one. The photovoltaic film passes over track one and track two in sequence. The rear end of track two is connected to the slitting machine, and the floating tension detection mechanism is provided between track two and the slitting machine.

[0011] Furthermore, a temperature measurement module and a wind-controlled temperature box are provided in the transition zone. The probe of the temperature measurement module and the cooling air vent of the wind-controlled temperature box are both set towards the area of ​​the transition zone that passes through the photovoltaic film. The temperature measurement module provides real-time feedback on the surface temperature gradient of the photovoltaic film and adjusts the running speed and air cooling intensity of the double-layer mesh belt section accordingly.

[0012] Furthermore, the slitting machine includes a cutting roller, which cuts a single row of wide photovoltaic film into multiple rows of narrow photovoltaic film. Each row of narrow photovoltaic film is connected to one set of the winding machine. The cutting roller is driven by a high-precision servo and, in conjunction with a size positioning system, achieves a slitting positioning accuracy of ±1mm. The winding machine includes a winding roller, the circumferential surface of which is covered with a ceramic coating, which has both heat conduction and temperature equalization functions as well as static electricity dissipation functions, ensuring that the flatness of the roll end face is ≤0.15mm and the tightness difference is ≤3%.

[0013] Furthermore, a floating roller is provided between the fourth cold roller and the thickness gauge. This floating roller adopts a double-bearing swing arm counterweight support structure, and its axial runout is ≤1.5μm. It is used in conjunction with a high-response linear displacement sensor to monitor the swing angle deviation in real time. This floating roller, together with the fourth and fifth cold rollers in front and behind it, forms the first-level tension buffer triangle zone. The change in the angle encoding mechanism is obtained by the up and down swing of the floating roller, which compensates for the instantaneous tension change caused by the fluctuation of the thermal shrinkage rate of the photovoltaic film. When the angle deviation exceeds the threshold, the system automatically fine-tunes the speed of the second cooling roller group and the temperature control parameters to correct the problem, so that the wide-range CV value is stabilized within ±0.5%.

[0014] Furthermore, a floating roller is provided between the cold roller six and the double-layer mesh belt section. This floating roller is connected to the added dynamic eccentricity compensation module, which can offset the edge tension gradient caused by the change in the width of the photovoltaic film in real time. The floating roller, the cold roller six, and the upper layer of the double-layer mesh belt section form a second-level tension buffer triangle zone.

[0015] Furthermore, a floating roller is provided between the second track and the cutter roller, an active traction roller is provided between the winding machine and the cutter roller, an active traction roller is provided one-to-one in front of the winding machine, and a floating roller is provided between each winding machine and the corresponding active traction roller.

[0016] Furthermore, all floating rollers are made of high-rigidity aluminum alloy roller body, with hard chrome plated and mirror polished (Ra≤0.025μm). The shaft end integrates a high-precision angle encoder (resolution 0.1°) and a strain gauge tension sensor (range 0~50N, accuracy ±0.02N).

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: This invention discloses an intelligent casting line for photovoltaic film, which automatically matches the roller speed during the extrusion and embossing process of photovoltaic film and the winding process. It is equipped with a multi-stage cooling device to ensure uniform tension of photovoltaic film during the cooling process, so that photovoltaic film will not be stretched or loosened. All operation processes are automated, reducing human loss costs. To achieve constant tension transmission, this intelligent production casting line monitors and detects the actual speed of each roller in real time. By introducing a floating roller tension system, it automatically adjusts the speed of each active roller to achieve closed-loop control. The production line's operating speed has increased from 18m / min in the traditional production line to 32m / min (+77.8%), and the winding tension fluctuation has been stabilized at ±0.15N, a 97% reduction compared to the 5N baseline value. Adding a double-layer mesh belt device extends the cooling path of the adhesive film, allowing for more precise delivery of the adhesive film surface temperature without increasing the length of the adhesive film production line, thus saving installation space. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 for Figure 1 Enlarged schematic diagram of the structure at point A in the middle; Figure 3 This is a schematic diagram of the tension detection mechanism in this invention; Figure 4 This is a schematic diagram of the transition region in this invention; Numbering on the map: 1. Mesh belt conveyor; 2. Three-roll embossing machine; 3. Cooling roller assembly 1; 4. Thickness gauge; 5. Cooling roller assembly 2; 6. Transition zone; 7. Slitting machine; 8. Winding machine; 9. Tension detection mechanism; 10. Extrusion die; 21. Embossing roller; 22. Matching extrusion roller; 23. Cold roller one; 31. Cold roller two; 32. Cold roller three; 33. Cold roller four; 51. Cold roller five; 52. Cold roller six; 61. Double-layer mesh belt section; 62. Track section; 621. Track one; 622. Track two; 71. Cutting roller; 81. Take-up roller; 91. Swing arm one; 92. Swing arm two; 93. Floating roller; 94. Fixed guide roller; 95. Tension sensor; 96. Angle encoding mechanism; 97. Configuring weights. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. In the description of the present invention, it should be noted that if the terms "upper", "lower", "middle", "inner", "outer" are used to indicate the direction or positional relationship based on the direction or positional relationship shown in the accompanying drawings, they are only for the convenience of describing the technical solutions of the present 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 the present invention.

[0020] Please see Figures 1-4 As shown, a photovoltaic encapsulant film intelligent casting line includes several active traction rollers, an extrusion die head 10 connected from front to back, a mesh belt machine 1, a three-roll embossing machine 2, a transition zone 6, a slitting machine 7, and ≥2 sets of winding machines 8. A cooling mechanism and a thickness measuring mechanism are provided between the three-roll embossing machine unit 2 and the transition zone 6. The cooling mechanism includes a cooling roller group 3 and a cooling roller group 5 arranged in front and behind. The thickness measuring mechanism is a thickness gauge 4, which is sandwiched between the cooling roller group 3 and the cooling roller group 5. The photovoltaic film passes through the thickness gauge 4 laterally. The transition zone 6 is provided with a double-layer mesh belt section 61 and a track section 62 from top to bottom. The double-layer mesh belt section 61 includes upper and lower double-layer parallel PTFE woven conveyor mesh belts with the following parameters: mesh size: 3mm×5mm, tension independently adjustable (0~15N, adjustment step 0.1N), running speed adjustable from 0~45m / min, and equipped with a correction device with a correction response time ≤35ms and repeatability accuracy ±0.05mm. The front-to-back length of the track section 62 is greater than that of the double-layer mesh belt section 61. The track section 62 includes track one 621 and track two 622 connected front to back. The rear end of track two 622 is connected to the slitting machine 7. The casting line adopts a horizontal three-section independent temperature control design. The first section maintains 25±2℃ to stabilize the surface state of the photovoltaic film. The second section gradually cools down to 23±1.5℃ to suppress the release of residual stress in the photovoltaic film. The third section maintains a constant temperature of 20±1℃ to complete the final shaping of the photovoltaic film. The temperature control response time of each section is ≤8 seconds, and the temperature uniformity is ≤±0.5℃. The casting line is equipped with several active traction rollers, each equipped with a servo motor (rated torque ≥12N·m, dynamic response bandwidth ≥20Hz) and a high linearity photoelectric encoder (pulse resolution ≥50ppr). Together with the edge computing unit, it achieves millisecond-level synchronous adjustment of roller speed (command delay ≤2ms, position synchronization error ≤±0.01mm). The servo driver has a built-in PID parameter self-tuning function, supports tension feedforward compensation and speed loop cross-coupling control, and ensures the consistency of multi-roller coordinated response. The slitting machine 7 includes a cutting roller 71, which cuts a single row of wide photovoltaic film into multiple rows of narrow photovoltaic film. Each row of narrow photovoltaic film is connected to a winding machine 8. It also includes a floating tension detection mechanism 9, which is located between the cooling roller group 3 and the thickness gauge 4, between the cooling roller group 5 and the double-layer mesh belt section 61 (upper layer), between the crawler 2 622 and the slitting machine 7, and between the slitting machine 7 and the winding machine 8. The floating tension detection mechanism 9 includes: The first swing arm 91 and the second swing arm 92 are fixedly connected to form a crank lever structure, with a swing shaft in the middle to form a fulcrum of rotation. The floating roller 93 is rotatably connected to the end of the swing arm 91 away from the pivot point. At the end of the swing arm 92 furthest from the pivot point, there is a weight 97. The weight 97 provides a constant tension force to the floating roller 93 through the lever torque by its own weight. It is the core of the tension setting. By changing the weight 97 of different weights, the set tension value of the system can be adjusted. The swing shaft is coaxially connected to a strain gauge tension sensor 95 and an angle encoding mechanism 96, which can detect the deflection angle of the crank lever structure in real time without gaps, indirectly reflecting the real-time tension of the photovoltaic film, and output analog / digital signals to the back-end control system. On the film-carrying path of the photovoltaic film, fixed guide rollers 94 are provided before and after the floating roller 93. The fixed guide rollers 94 are in a fixed position and are used to constrain the film-carrying path of the photovoltaic film and provide a stable wrap angle for the floating roller 93. The floating roller 93 swings synchronously with the crank lever structure and directly contacts the photovoltaic film, serving as a direct tension action and detection carrier.

[0021] Working process of floating tension detection mechanism 9: 1. Steady-state balance: During normal and stable conveying, the torque generated by the photovoltaic film tension on the floating roller 93 is balanced with the gravitational torque of the weight 97. The crank lever structure is maintained at the preset balance angle, and the photovoltaic film tension remains constant. 2. Fluctuation Buffering and Detection: When the upstream and downstream conveying speeds are mismatched and the photovoltaic film tension increases, the photovoltaic film will pull the floating roller 93 to overcome the counterweight torque, causing the crank lever structure to deflect upward; when the photovoltaic film tension decreases, the counterweight torque becomes dominant, the crank lever structure deflects downward, and the floating roller 93 tightens the photovoltaic film; at the same time as the crank lever structure deflects, the sensor at the pivot point outputs an angle change signal in real time, and the tension fluctuation is approximately proportional to the deflection angle of the crank lever structure. 3. Closed-loop correction: After receiving the angle signal, the control system adjusts the speed of the unwinding / rewinding rollers through the PID algorithm (if the tension is too high, the unwinding speed is increased and the rewinding speed is decreased; if the tension is too low, the unwinding speed is increased and the rewinding speed is decreased), driving the crank lever structure back to the equilibrium position, and finally realizing dynamic constant tension control of photovoltaic film conveying. The floating tension detection mechanism 9 between the cooling roller group 2 5 and the double-layer mesh belt section 61 is equipped with a dynamic eccentricity compensation module.

[0022] The three-roll embossing unit 2 includes an embossing roller 21 and a matching extrusion roller 22 arranged close together, with a photovoltaic film passing through between them; it also includes a cold roller 23 arranged away from the mesh belt machine 1, with the embossing roller 21 arranged between the matching extrusion roller 22 and the cold roller 23.

[0023] The cooling roller group 3 includes a second cooling roller 31, a third cooling roller 32 and a fourth cooling roller 33 arranged in parallel in sequence. The setting height of the third cooling roller 32 is higher than that of the second cooling roller 31 and the fourth cooling roller 33. The photovoltaic film is fed sequentially from below the second cold roller 31, above the third cold roller 32, and below the fourth cold roller 33.

[0024] The second cooling roller group 5 includes a fifth cooling roller 51 and a sixth cooling roller 52 arranged in parallel in sequence, with the sixth cooling roller 52 arranged at a higher height than the fifth cooling roller 51. In this process, the photovoltaic film is fed sequentially from below the cold roller 51 and above the cold roller 6.

[0025] The track section 62 includes track one 621 and track two 622 connected front to back and set at the same height. The front end of track one 621 is connected to double-layer mesh belt section 61. Double-layer mesh belt section 61 conveys photovoltaic film from above to track one 621. The photovoltaic film passes sequentially above track one 621 and track two 622. The rear end of track two 622 is connected to slitting machine 7. A floating tension detection mechanism 9 is set between track two 622 and slitting machine 7.

[0026] The transition zone 6 is equipped with a temperature measurement module and a wind control temperature box. The probe of the temperature measurement module and the cooling air vent of the wind control temperature box are both set towards the area of ​​the photovoltaic film in the transition zone 6. The temperature measurement module provides real-time feedback on the surface temperature gradient of the photovoltaic film and adjusts the running speed and air cooling intensity of the double-layer mesh belt section 61 in conjunction with it.

[0027] The slitting machine 7 includes a cutting roller 71, which cuts a single row of wide photovoltaic film into multiple rows of narrow photovoltaic film. Each row of narrow photovoltaic film is connected to a winding machine 8. The cutting roller 71 is driven by a high-precision servo and, together with a size positioning system, achieves a slitting positioning accuracy of ±1mm. The winding machine 8 includes a winding roller 81, whose circumferential surface is coated with a ceramic coating, which has both heat conduction and temperature equalization functions as well as static electricity dissipation functions, ensuring that the flatness of the roll end face is ≤0.15mm and the tightness difference is ≤3%. The flatness of the winding end face is improved to ≤0.15mm, reducing the adhesion of the photovoltaic film.

[0028] A floating roller 93 is installed between the cold roller 4 33 and the thickness gauge 4. The floating roller 93 adopts a double bearing swing arm counterweight support structure, and its axial runout is ≤1.5μm. With the help of a high-response linear displacement sensor, the swing angle deviation is monitored in real time. The floating roller 93, together with the cold roller 4 33 and the cold roller 51 in front and behind it, form the first-level tension buffer triangle zone. The change in the value measured by the angle encoding mechanism 96 is obtained by the up and down swing of the floating roller 93, which compensates for the instantaneous tension change caused by the fluctuation of the thermal shrinkage rate of the photovoltaic film. When the angle deviation exceeds the threshold, the system automatically fine-tunes the speed of the cooling roller group 2 5 and the temperature control parameters to correct the problem, so that the width CV value is stabilized within ±0.5%.

[0029] A floating roller 93 is installed between the cold roller 6 (52) and the double-layer mesh belt section 61. This floating roller 93 is connected to an additional dynamic eccentricity compensation module to offset the edge tension gradient caused by the width variation of the photovoltaic film in real time. The floating roller 93, together with the cold roller 6 (52) and the upper layer of the double-layer mesh belt section 61, forms a second-level tension buffer triangle zone, which, in conjunction with the edge tension sensor array, achieves closed-loop control of the tension distribution in the width direction of the photovoltaic film. When the photovoltaic film enters the double-layer mesh belt section 61, the system synchronously adjusts the initial tension of the top layer of the double-layer mesh belt section 61 and the output power of the air control temperature box based on the swing angle change rate of the floating roller 93, ensuring that the deformation rate of the photovoltaic film is ≤0.5% before composite molding. The photovoltaic film completes stress homogenization and... Once the shape is finalized, the photovoltaic film enters the track section 62. Before entering the track 621, the surface temperature of the photovoltaic film is precisely controlled within the range of 22±2℃, providing an ideal mechanical state for subsequent slitting. Both the double-layer mesh belt section 61 and the track section 62 support the photovoltaic film from below, ensuring that the photovoltaic film naturally extends without external force and controlling micro-folds and residual internal stress. The double-layer mesh belt section 61 is equipped with an airbag correction device with a correction response time ≤35ms and a repeatability accuracy of ±0.05mm. Combined with a high-resolution infrared edge detection sensor, it identifies the deviation trend of the photovoltaic film in real time and dynamically adjusts the airbag pressure difference to ensure that the straightness deviation of the entire photovoltaic film edge is ≤0.2mm under high-speed operation at 35m / min.

[0030] A floating roller 93 is installed between the track 622 and the cutter roller 71. An active traction roller is installed between the winding machine 8 and the cutter roller 71. An active traction roller is installed one-to-one in front of each winding machine 8. A floating roller 93 is installed between each winding machine 8 and its corresponding active traction roller. Specifically, taking two winding machines 8 as an example, floating rollers 93 are installed before and after the cutter roller 71 to ensure the tension of the film cutting the edge of the cutter roller 71. A floating roller 93 is installed between the first winding machine 8 and its corresponding active traction roller in front of it. A floating roller 93 is installed before and after the active traction roller in front of the second winding machine 8 to ensure that the photovoltaic film entering the dual winding station has a balanced tension and a precise and controllable axial position, ensuring that the winding is wrinkle-free, does not deviate, and has a neat end face, with a winding tension fluctuation ≤ ±0.3N. Each floating roller 93 shifts according to the change in photovoltaic film tension, and the angle sensor shifts accordingly. The system calculates the shift in real time and outputs closed-loop control commands, automatically adjusting the speed of each active traction roller. This achieves dynamic tension balance with a millisecond-level response, keeping the tension fluctuation of the entire line within ±0.15N. The winding machine 8 supports automatic roll changing and seamless tension switching, reducing the roll changing time to within 8 seconds.

[0031] Further optimization of the design: all floating rollers 93 are made of high-rigidity aluminum alloy roller body, with hard chrome plated and mirror polished (Ra≤0.025μm). The shaft end integrates a high-precision angle encoder (resolution 0.1°) and a strain gauge tension sensor (range 0~50N, accuracy ±0.02N).

[0032] In this technical solution, high-precision sensors collect tension, temperature, and linear velocity data in real time between the various devices, and the edge computing unit dynamically calculates the optimal roller speed matching curve. The floating roller angle sensor serves as the control command to intelligently adjust the roller speed and transition zone temperature. Cooling roller groups one and two adopt segmented temperature control technology to precisely regulate the cooling rate of each segment of the photovoltaic film, avoiding deformation and thickness deviation caused by uneven thermal stress.

[0033] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. For those skilled in the art, various changes, modifications or additions made without departing from the concept of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A smart photovoltaic encapsulant film casting line, comprising a plurality of active traction rollers, characterized in that, It includes an extrusion die (10), a mesh belt machine (1), a three-roll embossing machine (2), a transition zone (6), a slitting machine (7), and ≥2 sets of winding machines (8) connected from front to back. A cooling mechanism and a thickness measuring mechanism are provided between the three-roll embossing machine unit (2) and the transition zone (6). The cooling mechanism includes a cooling roller group one (3) and a cooling roller group two (5). The thickness measuring mechanism is a thickness gauge (4), which is sandwiched between the cooling roller group one (3) and the cooling roller group two (5). The transition zone (6) is provided with a double-layer mesh belt section (61) and a track section (62) from top to bottom. The casting line adopts a horizontal three-section independent temperature control design. The first section maintains 25±2℃, the second section gradually cools down to 23±1.5℃, and the third section maintains a constant temperature of 20±1℃. The slitting machine (7) cuts a single row of wide photovoltaic film into multiple rows of narrow photovoltaic film, and each row of narrow photovoltaic film is connected to a winding machine (8). It also includes a floating tension detection mechanism (9), which is located between the first cooling roller group (3) and the thickness gauge (4), between the second cooling roller group (5) and the double-layer mesh belt section (61), between the crawler section (62) and the slitting machine (7), and between the slitting machine (7) and the winding machine (8). The floating tension detection mechanism (9) includes: The crank lever structure is formed by the fixed connection of the first swing arm (91) and the second swing arm (92), with a swing shaft in the middle to form a fulcrum for rotation; A floating roller (93) is connected to the end of the swing arm (91) away from the pivot point; A weight (97) is connected to the end of the second swing arm (92) away from the pivot point; The swing shaft is coaxially connected to a strain gauge tension sensor (95) and an angle encoding mechanism (96). On the film-carrying path of the photovoltaic film, fixed guide rollers (94) are provided before and after the floating roller (93).

2. The intelligent photovoltaic encapsulant film casting line according to claim 1, characterized in that: The three-roll embossing machine unit (2) includes an embossing roller (21) and a matching extrusion roller (22) arranged close together, with a photovoltaic film passing through between them; it also includes a cold roller (23) arranged away from the mesh belt machine (1), with the embossing roller (21) arranged between the matching extrusion roller (22) and the cold roller (23).

3. The intelligent casting line for photovoltaic encapsulant film according to claim 2, characterized in that: The first cooling roller group (3) includes a second cooling roller (31), a third cooling roller (32) and a fourth cooling roller (33) arranged in parallel in sequence. The setting height of the third cooling roller (32) is higher than that of the second cooling roller (31) and the fourth cooling roller (33).

4. The intelligent casting line for photovoltaic encapsulant film according to claim 3, characterized in that: The second cooling roller group (5) includes a fifth cooling roller (51) and a sixth cooling roller (52) arranged in parallel in sequence. The height of the sixth cooling roller (52) is higher than that of the fifth cooling roller (51).

5. The intelligent casting line for photovoltaic encapsulant film according to claim 4, characterized in that: The track section (62) includes track one (621) and track two (622) connected front to back and set at the same height. The rear end of track two (622) is connected to the slitting machine (7). The floating tension detection mechanism (9) is provided between track two (622) and the slitting machine (7).

6. The intelligent casting line for photovoltaic encapsulant film according to claim 5, characterized in that: A temperature measuring module and a wind control temperature box are provided in the transition zone (6). The probe of the temperature measuring module and the cooling air vent of the wind control temperature box are both set towards the area of ​​the photovoltaic film in the transition zone (6).

7. The intelligent casting line for photovoltaic encapsulant film according to claim 6, characterized in that: The slitting machine (7) includes a cutting roller (71), which cuts a single row of wide photovoltaic film into multiple rows of narrow photovoltaic film. Each row of narrow photovoltaic film is connected to a winding machine (8). The winding machine (8) includes a winding roller (81), and the circumferential surface of the winding roller (81) is covered with a ceramic coating.

8. The intelligent casting line for photovoltaic encapsulant film according to claim 7, characterized in that: A floating roller (93) is provided between the fourth cold roller (33) and the thickness gauge (4). The floating roller (93) adopts a double bearing swing arm counterweight support structure, and its axial runout is ≤1.5μm. The floating roller (93) and the fourth cold roller (33) and the fifth cold roller (51) before and after it form the first-level tension buffer triangle area.

9. The intelligent casting line for photovoltaic encapsulant film according to claim 8, characterized in that: A floating roller (93) is provided between the cold roller six (52) and the double-layer mesh belt section (61), and the floating roller (93) forms a second-level tension buffer triangle area with the cold roller six (52) and the upper layer of the double-layer mesh belt section (61).

10. The intelligent casting line for photovoltaic encapsulant film according to claim 9, characterized in that: A floating roller (93) is provided between the second track (622) and the cutter roller (71), and an active traction roller is provided between the winding machine (8) and the cutter roller (71). The active traction rollers are provided one-to-one in front of the winding machine (8), and a floating roller (93) is provided between each winding machine (8) and the corresponding active traction roller.

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