Device for detecting welding quality of photovoltaic module

Abstract

The utility model discloses a device for detecting the welding quality of a photovoltaic module. The device is provided with an assembly line module, a four-edge restoration module, a visual guidance and appearance detection module, a height detection module, an X-ray moving module and a flat panel detector module, the four-edge restoration module clamps the materials and moves the materials to a working station; the visual guidance and appearance detection module can move back and forth and up and down to photograph materials; the height detection module can move back and forth and up and down to measure the height of the material; the X-ray moving module can move back and forth and up and down to carry out X-ray irradiation on materials; the flat panel detector module can move back and forth and up and down to an X-ray irradiation area. According to the utility model, the welding quality of the interior of the welded photovoltaic module can be detected, the occurrence of leak detection is avoided, and the risk of leak detection is eliminated.

Description

Technical Field

[0001] The utility model relates to the photovoltaic field, in particular to a device for detecting the welding quality of a photovoltaic component wire box. Background Art

[0002] In the production process of photovoltaic modules, multiple junction boxes need to be welded on the photovoltaic panels. Laser welding is generally used for the welding of junction boxes. It is a non-contact, high-efficiency and precision welding method using laser beam as heat source. The hot melting effect of laser welding is more stable than conventional soldering, and the welding tensile force is higher, which improves the reliability and service life of photovoltaic modules. The welding speed is faster than the general contact welding speed. However, there is no reliable detection method to achieve this laser.

[0003] There are currently two ways to do testing:

[0004] 1. After laser welding, it is checked by naked eyes or by manual inspection using tools such as screwdrivers. There are certain differences in the judgment methods of each person in the two situations. There is also the risk of missed inspections for a long time or due to fatigue. The latter may also cause damage and influence on the appearance and performance of the main body of the junction box, affecting the quality of the product.

[0005] 2. Visual inspection. However, for this new type of welding inspection, we could only use industrial cameras to collect images of the welding surface and use conventional appearance inspection algorithms or appearance AOI inspection. Both of them cannot achieve the expected detection rate. There is still the possibility of missed inspection and outflow. Because for welding, we need to inspect the internal structure of the welding, whether the two are tightly fitted and whether there is a fusion zone between the two.

[0006] In summary, a major problem with existing detection technologies is the risk of missing detection of laser welding of junction boxes; Utility Model Content

[0007] In view of the defects in the prior art, the utility model provides a device for detecting the welding quality of photovoltaic modules. The device performs X-ray inspection on photovoltaic panels welded with junction boxes, and can detect the welding quality inside the photovoltaic modules after welding, thereby avoiding the occurrence of missed detection and eliminating the risk of missed detection.

[0008] In order to solve the above technical problems, the technical solution adopted by the utility model is:

[0009] A device for detecting the welding quality of photovoltaic modules, comprising a protective shell, a material inlet is arranged on the front side of the protective shell, and a material outlet is arranged on the rear side, characterized in that: an assembly line module, a four-side alignment module, a visual guidance and appearance detection module, a height detection module, an X-ray moving module and a flat panel detector module are arranged in the protective shell; the assembly line module is installed facing the material inlet and the material outlet of the protective shell, and the material enters the assembly line module at the material inlet, and after the detection is completed, the assembly line module is sent out from the material outlet; the four-side alignment module is installed on the left and right sides of the protective shell, and after the material is sent into the protective shell by the assembly line module, the four-side alignment module rises , clamp the material, position it front, back, left, and right, and move the material to the work position; the visual guidance and appearance inspection module is located above the assembly line module, and after the material enters the work position, it can move back and forth and up and down to take pictures of the material; the height detection module is located above the assembly line module, and after the material enters the work position, it can move back and forth and up and down to measure the height of the material; the X-ray moving module is located above the assembly line module, and after the material enters the work position, it can move back and forth and up and down to irradiate the material with X-rays; the flat-panel detector module is located below the assembly line module, and after the material enters the work position, it can move back and forth and up and down to the X-ray irradiation area.

[0010] The assembly line module includes four conveyor belts, each conveyor belt is sleeved on a set of synchronous pulleys, and the four sets of synchronous pulleys are sleeved on the transmission shaft, and the transmission shaft outputs power through the motor. The motor drives the transmission shaft to rotate, the rotating shaft drives the four sets of synchronous pulleys to rotate, and the synchronous pulleys drive the conveyor belts to rotate, so as to achieve the purpose of inputting materials from the material inlet and outputting materials from the material outlet.

[0011] The four-side alignment module includes left and right linear guides perpendicular to the conveyor belt and front and rear linear guides parallel to the conveyor belt, a clamping block is installed on the front and rear linear guides, and the front and rear linear guides are slidably installed on the left and right linear guides. Under the action of the power source, the clamping block can slide forward and backward on the front and rear linear guides, and the front and rear linear guides can slide left and right on the left and right linear guides. As for how the power source drives the clamping block and the sliding of the front and rear linear guides, this is a conventional technology and will not be repeated again, such as by driving by a cylinder.

[0012] The visual guidance and appearance inspection module includes a connector, a guide rail, a single-axis robot and a camera. The guide rail is assumed to be inside the protective housing in the front-to-back direction. The single-axis robot is installed on the guide rail through a connector. The camera is installed on the single-axis robot. The single-axis robot can slide forward and backward on the guide rail under the action of a power source. The single-axis robot can drive the camera to slide up and down. The visual guidance and appearance inspection module is used to shoot materials, one is to detect the appearance quality of welding, and the other is to analyze whether the material reaches the inspection area.

[0013] The height detection module is used to detect the height of the material. Since the material is a photovoltaic panel assembly with a junction box welded on it, the height detection module is used to detect the height of the junction box. It includes a height measuring instrument, a connector, a guide rail and a single-axis robot. The single-axis robot is installed on the guide rail through the connector, and the height measuring instrument is installed on the single-axis robot. The single-axis robot can slide back and forth on the guide rail under the action of the power source, and the single-axis robot can drive the height measuring instrument to slide up and down.

[0014] The X-ray mobile module includes an X-ray emitter, a connector, a guide rail and a single-axis robot. The single-axis robot is installed on the guide rail through the connector. The X-ray emitter is installed on the single-axis robot. The single-axis robot can slide back and forth on the guide rail under the action of a power source, and the single-axis robot can drive the X-ray emitter to slide up and down.

[0015] The flat-panel detector module includes an X-ray receiver, a connector, a guide rail and a single-axis robot. The single-axis robot is installed on the guide rail through the connector. The X-ray receiver is installed on the single-axis robot. The single-axis robot can slide back and forth on the guide rail under the action of a power source, and the single-axis robot can drive the X-ray receiver to slide up and down.

[0016] The single-axis robot is actually a device that can slide up and down in a protective shell. The specific structure is varied. For example, it includes a vertical track with a sliding member installed on the vertical track. The sliding member is connected to a cylinder, and the cylinder pushes the sliding member to slide up and down on the vertical track.

[0017] The beneficial effects of the utility model are embodied in:

[0018] This utility model uses X-ray nondestructive testing to solve the problem of manual missed inspection after laser welding of the junction box. Through visual guidance and appearance inspection modules, it can detect tiny defects in the product. At the same time, it can detect internal defects of the product without destroying the product, avoiding the inaccurate detection accuracy of industrial cameras. The real-time generated images can quickly feedback abnormal conditions in production, thereby improving production efficiency and avoiding batch defects. For manual labor, it can reduce the risk of secondary defects caused by fatigue work and manual inspection. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In order to more clearly illustrate the specific implementation of the utility model or the technical solution in the prior art, the following is a brief introduction to the drawings required for the specific implementation or the prior art description. In all the drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, each element or part is not necessarily drawn according to the actual scale.

[0020] Figure 1It is a schematic diagram of the overall structure of the utility model;

[0021] Figure 2 This is a schematic diagram of the internal structure of the utility model;

[0022] Figure 3 It is a schematic diagram of the structure of the assembly line module and the four-side correction module;

[0023] Figure 4 This is a schematic diagram of the structure of the visual guidance, appearance detection module and height detection module;

[0024] Figure 5 This is a schematic diagram of the structure of the X-ray mobile module and the flat-panel detector module.

[0025] In the attached drawings, 1. rack, 2. removable cover plate, 3. lead plate protection, 4. movable safety door, 5. assembly line module, 6. four-side alignment module, 7. visual guidance and appearance inspection module, 8. height detection module, 9. X-ray mobile module, 10. flat panel detector module. DETAILED DESCRIPTION

[0026] The following embodiments of the technical solution of the utility model are described in detail in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the utility model, and are therefore only used as examples, and cannot be used to limit the protection scope of the utility model.

[0027] The utility model includes a protective shell, and the specific structure of the protective shell is: first, a frame 1 is assembled by welding 60*60 and 60*120 rectangular pipes, and then the outside of the frame is covered by a radiation protection shield, which is composed of a detachable sealing plate 2, and the sealing plate contains a 3mm lead plate inside, forming a lead plate protection 3, which is fixed to the outside of the frame by bolts, and a maintenance safety door is opened around it. The shell is provided with a movable safety door 4 with the same structure as the protective cover, and contains a 3mm lead plate. In addition to the manually openable safety movable door, when working, the shell is provided with a material inlet and a material outlet, and also has a safety door that moves up and down, which is controlled by a cylinder.

[0028] The frame is provided with an assembly line module 5, a four-side alignment module 6, a visual guidance and appearance detection module 7, a height detection module 8, an X-ray moving module 9 and a flat panel detector module 10; the assembly line module is installed facing the material inlet and the material outlet of the protective shell, and the material enters the assembly line module at the material inlet. After the detection is completed, the assembly line module will be sent out from the material outlet; the four-side alignment module is installed on the left and right sides of the protective shell. After the material is sent into the protective shell by the assembly line module, the four-side alignment module rises to clamp the material, and positions it front, back, left, and right to move the material to the working position. ; The visual guidance and appearance inspection module is located above the assembly line module. After the material enters the working position, it can move forward and backward and up and down to take pictures of the material; the height detection module is located above the assembly line module. After the material enters the working position, it can move forward and backward and up and down to measure the height of the material; the X-ray moving module is located above the assembly line module. After the material enters the working position, it can move forward and backward and up and down to irradiate the material with X-rays; the flat-panel detector module is located below the assembly line module. After the material enters the working position, it can move forward and backward and up and down to the X-ray irradiation area.

[0029] The assembly line module includes four conveyor belts, each conveyor belt is sleeved on a set of synchronous pulleys, and the four sets of synchronous pulleys are sleeved on the transmission shaft, and the transmission shaft outputs power through the motor. The motor drives the transmission shaft to rotate, the rotating shaft drives the four sets of synchronous pulleys to rotate, and the synchronous pulleys drive the conveyor belts to rotate, so as to achieve the purpose of inputting materials from the material inlet and outputting materials from the material outlet.

[0030] The four-side alignment module includes left and right linear guides perpendicular to the conveyor belt and front and rear linear guides parallel to the conveyor belt, a clamping block is installed on the front and rear linear guides, and the front and rear linear guides are slidably installed on the left and right linear guides. Under the action of the power source, the clamping block can slide forward and backward on the front and rear linear guides, and the front and rear linear guides can slide left and right on the left and right linear guides. As for how the power source drives the clamping block and the sliding of the front and rear linear guides, this is a conventional technology and will not be repeated again, such as by driving by a cylinder.

[0031] The visual guidance and appearance inspection module includes a connector, a guide rail, a single-axis robot and a camera. The guide rail is assumed to be inside the protective housing in the front-to-back direction. The single-axis robot is installed on the guide rail through a connector. The camera is installed on the single-axis robot. The single-axis robot can slide forward and backward on the guide rail under the action of a power source. The single-axis robot can drive the camera to slide up and down. The visual guidance and appearance inspection module is used to shoot materials, one is to detect the appearance quality of welding, and the other is to analyze whether the material reaches the inspection area.

[0032] The height detection module is used to detect the height of the material. Since the material is a photovoltaic panel assembly with a junction box welded on it, the height detection module is used to detect the height of the junction box. It includes a height measuring instrument, a connector, a guide rail and a single-axis robot. The single-axis robot is installed on the guide rail through the connector, and the height measuring instrument is installed on the single-axis robot. The single-axis robot can slide back and forth on the guide rail under the action of the power source, and the single-axis robot can drive the height measuring instrument to slide up and down.

[0033] The X-ray mobile module includes an X-ray emitter, a connector, a guide rail and a single-axis robot. The single-axis robot is installed on the guide rail through the connector. The X-ray emitter is installed on the single-axis robot. The single-axis robot can slide back and forth on the guide rail under the action of a power source, and the single-axis robot can drive the X-ray emitter to slide up and down.

[0034] The flat-panel detector module includes an X-ray receiver, a connector, a guide rail and a single-axis robot. The single-axis robot is installed on the guide rail through the connector. The X-ray receiver is installed on the single-axis robot. The single-axis robot can slide back and forth on the guide rail under the action of a power source, and the single-axis robot can drive the X-ray receiver to slide up and down.

[0035] The single-axis robot is actually a device that can slide up and down in a protective shell. The specific structure is varied. For example, it includes a vertical track with a sliding member installed on the vertical track. The sliding member is connected to a cylinder, and the cylinder pushes the sliding member to slide up and down on the vertical track.

[0036] It should be noted that, unless otherwise specified, the technical terms or scientific terms used in this application should have the common meanings understood by technicians in the field to which the utility model belongs.

[0037] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the utility model, rather than to limit it. Although the utility model has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein by equivalents. These modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the utility model, and they should all be included in the scope of the claims and specification of the utility model.

Claims

1. A device for detecting the welding quality of photovoltaic modules, comprising a protective housing, a material inlet is arranged on the front side of the protective housing, and a material outlet is arranged on the rear side, characterized in that: The protective shell is equipped with an assembly line module, a four-side alignment module, a visual guidance and appearance detection module, a height detection module, an X-ray moving module and a flat panel detector module; The assembly line module is installed facing the material inlet and material outlet of the protective shell. The material enters the assembly line module at the material inlet. After the inspection is completed, the assembly line module will send it out from the material outlet; the four-side alignment module is installed on the left and right sides of the protective shell. After the material is sent into the protective shell by the assembly line module, the four-side alignment module rises to clamp the material, and positions it front, back, left, and right to move the material to the working position; the visual guidance and appearance inspection module is located above the assembly line module. After the material enters the working position, it can move back and forth and up and down to take pictures of the material; the height detection module is located above the assembly line module. After the material enters the working position, it can move back and forth and up and down to measure the height of the material; the X-ray moving module is located above the assembly line module. After the material enters the working position, it can move back and forth and up and down to irradiate the material with X-rays; the flat-panel detector module is located below the assembly line module. After the material enters the working position, it can move back and forth and up and down to the X-ray irradiation area.

2. The device for detecting the welding quality of photovoltaic modules according to claim 1, characterized in that: The assembly line module comprises four conveyor belts, each of which is sleeved on a set of synchronous pulleys, and the four sets of synchronous pulleys are sleeved on a transmission shaft, and the transmission shaft outputs power through a motor.

3. The device for detecting the welding quality of photovoltaic modules according to claim 1, characterized in that: The four-side alignment module includes left and right linear guides perpendicular to the conveyor belt and front and rear linear guides parallel to the conveyor belt. Clamping blocks are installed on the front and rear linear guides. The front and rear linear guides are slidably installed on the left and right linear guides. Under the action of the power source, the clamping blocks can slide back and forth on the front and rear linear guides, and the front and rear linear guides can slide left and right on the left and right linear guides.

4. The device for detecting the welding quality of photovoltaic modules according to claim 1, characterized in that: The visual guidance and appearance inspection module includes a connector, a guide rail, a single-axis robot and a shooting camera. The guide rail is assumed to be inside the shell along the front-to-back direction of the protective shell. The single-axis robot is installed on the guide rail through a connector. The shooting camera is installed on the single-axis robot. The single-axis robot can slide back and forth on the guide rail under the action of a power source, and the single-axis robot can drive the shooting camera to slide up and down.

5. The device for detecting the welding quality of photovoltaic modules according to claim 1, characterized in that: The height detection module is used to detect the height of the material. Since the material is a photovoltaic panel assembly with a junction box welded on it, the height detection module is used to detect the height of the junction box. It includes a height measuring instrument, a connector, a guide rail and a single-axis robot. The single-axis robot is installed on the guide rail through the connector, and the height measuring instrument is installed on the single-axis robot. The single-axis robot can slide back and forth on the guide rail under the action of the power source, and the single-axis robot can drive the height measuring instrument to slide up and down.

6. The device for detecting the welding quality of photovoltaic modules according to claim 1, characterized in that: The X-ray mobile module includes an X-ray emitter, a connector, a guide rail and a single-axis robot. The single-axis robot is installed on the guide rail through the connector. The X-ray emitter is installed on the single-axis robot. The single-axis robot can slide back and forth on the guide rail under the action of a power source, and the single-axis robot can drive the X-ray emitter to slide up and down.

7. The device for detecting the welding quality of photovoltaic modules according to claim 1, characterized in that: The flat-panel detector module includes an X-ray receiver, a connector, a guide rail and a single-axis robot. The single-axis robot is installed on the guide rail through the connector. The X-ray receiver is installed on the single-axis robot. The single-axis robot can slide back and forth on the guide rail under the action of a power source, and the single-axis robot can drive the X-ray receiver to slide up and down.

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