Polygonal winding integrated cylinder for conductive wires of stacked gate battery
By designing a polygonal integrated winding cylinder for the conductive wires of stacked grid batteries, the shortcomings of traditional winding cylinders in terms of precision and maintenance are solved, achieving precise layout and stable welding of high-density conductive wires, and reducing production costs and maintenance difficulty.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- CHANGZHOU SHICHUANG ENERGY CO LTD
- Filing Date
- 2025-05-06
- Publication Date
- 2026-05-01
AI Technical Summary
In existing photovoltaic module production, the traditional winding drum structure has problems such as large precision errors, complex maintenance, and inability to achieve high-density conductive wire layout of stacked grid cells. In particular, when the number of conductive wires exceeds 100, it is difficult to achieve precise alignment and stable welding.
A polygonal integrated winding cylinder for conductive wires of stacked grid batteries is designed. It adopts an integrally molded roller body, equipped with multiple winding racks and support rods. The precise positioning and stability of the conductive wires are ensured by evenly distributed wire grooves and magnetic attraction devices. The racks can be replaced individually to reduce maintenance costs.
It improves the accuracy and efficiency of winding and wiring, reduces production costs, ensures precise alignment of conductive wires with battery cells, simplifies the maintenance process of the winding drum, and meets the needs of high-density conductive wires for stacked grid batteries.
Smart Images
Figure CN224185618U_ABST
Abstract
Description
A polygonal integrated winding tube for conductive wires of stacked grid batteries Technical Field
[0001] This utility model relates to the field of photovoltaic technology, specifically to a polygonal winding tube for conductive wires of stacked grid cells. Background Technology
[0002] Global greenhouse gas emissions are escalating, and climate change is a serious problem. The international community's demand and pressure to reduce carbon emissions are increasing year by year. Traditional fossil fuels face problems such as price fluctuations, resource depletion, and environmental pollution, making energy transition imperative. Solar energy, as a clean and renewable energy source, has broad application prospects, and photovoltaic (PV) power generation represents the ultimate direction for new energy in the long term. In the long run, due to its enormous potential, PV power generation will become the mainstay of the world's energy supply. Therefore, the production of PV modules is the most crucial link in PV power generation. How to improve the power generation efficiency of modules has always been a research topic for major manufacturers. Solar cells, as the core component of modules, are constantly being updated and developed, leading to various cell technologies. To better improve the power generation of solar cells, increase emissivity, and reduce production costs, we have adopted a gridless, densely packed conductive wire (e.g., 190 conductive wires) cell manufacturing process to achieve this goal. This technology is called tandem grid cell technology. Currently used stacked grid welding machines employ a cylindrical winding method to shape the solar cells into an arc. The cells are first attached to the cylinder, and then conductive wires are wound around them, applying pressure to the cells to achieve welding. This method requires extremely high winding precision, and the cells are already compressed into an arc shape. A polygonal roller winding method (e.g., a dodecagonal) is now used, ensuring that the conductive wires on each side remain straight, and then the cells are aligned with the conductive wires. Traditional stringing machines, which use a gripper to hold the conductive wires, cannot achieve close-packing of the wires. The polygonal roller winding method completely solves this problem. However, the current winding cylinder is formed by splicing a base plate and winding posts, which introduces errors during assembly, and replacing worn or damaged winding posts is cumbersome. Therefore, the current method manufactures the roller body as a single piece, with a pitched rack installed on the body. When the rack is damaged or worn, it can be replaced promptly without disassembling the entire cylinder, effectively reducing roller precision errors and subsequent maintenance costs. Summary of the Invention
[0003] The purpose of this invention is to provide a polygonal integrated winding cylinder for conductive wires of stacked grid batteries, so as to improve winding and wiring efficiency and control production costs.
[0004] To achieve the above objectives, this utility model provides the following technical solution:
[0005] A polygonal integrated winding cylinder for conductive wires of a stacked grid battery includes a roller body composed of two opposing rollers. Multiple winding racks are arranged between the two rollers, evenly distributed to form a regular polygon. Each winding rack has several grooves. The distance between the first groove and the end of the winding rack, counting from one end, satisfies the following condition: If the integrated winding cylinder has n winding racks, numbered sequentially from 1 to n, and the distance between the first groove of the first winding rack and its end is X1, the distance between the first groove of the i-th winding rack and its end is Xi, i = 2 to n, and the groove spacing on the winding rack is Y, then Xi = X1 + Y / n*(i-1).
[0006] Preferably, multiple support rods are provided between the two rollers, and the winding rack is supported on the support rods.
[0007] More preferably, the support rod is provided with a mounting groove, and the winding rack is installed in the mounting groove.
[0008] Preferably, the cross-section of the groove on the winding rack is triangular.
[0009] Preferably, a cushioning pad is provided on the outer side of the roller.
[0010] Preferably, a pull stud is installed on the outer side of the roller, and the position of the pull stud is matched with the mating mechanism on the winding mechanism on which the winding integral cylinder is to be installed.
[0011] Preferably, a magnetic attraction device is provided on the inner side of the roller body, which can be attracted to the press.
[0012] Compared with the prior art, the beneficial effects of this utility model are:
[0013] 1. The winding drum structure of this utility model solves the problem of making tape for dense grid arrangement of stacked grid batteries. Stacked grid batteries are completely different from conventional batteries. Conventional batteries generally use about 12, 16 or 20 welding strips, while stacked grid batteries can have more than 100 conductive wires. Therefore, it is impossible to achieve this using the traditional tape pulling method. Only the winding drum of this utility model can complete this dense grid arrangement.
[0014] 2. The winding drum structure of this utility model solves the accuracy problem of dense grid arrangement in stacked grid cells. The winding spacing of the conductive wires in the stacked grid cells needs to be consistent with the grid of the cell, with a tolerance of ±20um. Therefore, the position of the conductive wires is very important. We control the position of each conductive wire through the groove of the rack. As long as the processing accuracy of the rack is guaranteed, the position accuracy of the corresponding conductive wire falling in the groove can also be guaranteed. This lays a solid foundation for the next step of cell alignment.
[0015] 3. The winding drum structure of this utility model solves the problem of complicated rack replacement during the use of winding drums. During long-term use, the winding rack of the drum will inevitably wear down. With the winding drum structure of this utility model, the number of rack slots and the slot spacing can be adjusted according to the actual production needs. When the rack slots wear down, a new rack can be directly replaced, thus avoiding the problem of disassembling and assembling the drum. This not only reduces the cost of using the winding drum, but also makes it very convenient for later maintenance. Attached Figure Description
[0016] Figure 1 is a schematic diagram of the overall structure of the polygonal winding integrated cylinder for the conductive wire of the stacked grid battery of this utility model.
[0017] Figure 2 shows the support rods installed on the main body of the roller;
[0018] Figure 3 is a schematic diagram of the winding rack used on the polygonal winding integrated cylinder of the conductive wire of the stacked grid battery of this utility model.
[0019] Figure 4 is a schematic diagram of the application environment of the polygonal winding integrated cylinder for conductive wires of the stacked grid battery of this utility model.
[0020] In the diagram: 1. Roller body; 2. Roller; 3. Winding rack; 4. Support rod; 5. Buffer pad; 6. Magnetic suction device; 7. Pull pin; 8. Mounting groove; 9. Wire groove; 10. Winding mechanism; 11. Wire pulling mechanism; 12. Wire laying mechanism. Detailed Implementation
[0021] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0022] In the description of this utility model, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this utility model 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. Therefore, they should not be construed as limitations on this utility model. In addition, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.
[0023] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," and "connected," etc., should be interpreted broadly. For example, "connected" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.
[0024] Referring to Figure 1, the polygonal winding integrated cylinder for stacked grid solar cells of this utility model includes a drum body 1 and a winding rack 3. The drum body 1 is composed of a pair of rollers 2, and the winding rack 3 is installed between the rollers 2. For easy replacement and maintenance, a support rod 4 is installed between the rollers 2, and a mounting groove 8 is provided on the support rod 4. The winding rack 3 is installed in the mounting groove 8. The support rod 4 is evenly distributed on the entire circumference, forming a polygon whose side length is adapted to the specifications of the corresponding solar cell. When the solar cell to be wired is 182.2×97.5-190 (where 190 represents the number of conductive wires), 12 winding racks are usually used to form a 12-sided polygon.
[0025] The following will use a 12-sided roller as an example to further illustrate the solution of this utility model in detail.
[0026] As shown in Figure 1, the roller can be divided into several components:
[0027] Roller body 1: The roller body 1 can be made of high-strength alloy materials (such as aerospace aluminum, titanium alloy, etc., aerospace aluminum can be selected from the perspective of cost), as shown in Figure 2. The roller body 1 is provided with a support rod 4 so as to facilitate the detachable installation of the winding rack 3.
[0028] Wire-wound rack 3: The wire-wound rack can also be made of high-strength alloy material, as shown in Figure 3. Wire grooves 9 are formed on the wire-wound rack 3. The shape and depth of the grooves 9 can be determined according to the specifications of the conductive wire used. The number of grooves 9 on the wire-wound rack 3 is greater than the number of grid lines on each battery cell. Taking triangular conductive wire as an example, equilateral triangular grooves are formed on the wire-wound rack 3, with a vertex angle less than 60 degrees and a groove depth of 0.1-0.4 mm. A number greater than 190 is sufficient; generally, adding 10 more grooves can fully meet the requirements.
[0029] In addition, the roller is also equipped with a buffer pad 5, a magnetic attraction device 6, and a pull stud 7. The buffer pad 5 is used to reduce the cushioning during roller handling and clamping, such as a silicone pad. The magnetic attraction device 6 is a steel or iron part that can be attracted by a magnet and is used to attract the roller to the clamp. The pull stud 7 is used to match the roller with the corresponding fixing device when assembling the roller with the motor to ensure accurate positioning and stable assembly. For example, in one embodiment of this utility model, the matching device is a zero-point positioner on the motor, which makes the roller firmly installed on the motor and can ensure its repeatability within ±5μm.
[0030] The slots on the winding rack are formed under the following conditions: The distance between the first slot and the end of the winding rack, measured from one end of the rack, is calculated as follows: If the integrated winding cylinder has n winding racks, and these racks are numbered sequentially from 1 to n, and the distance between the first slot of the first winding rack and its end is X1, and the distance between the first slot of the i-th winding rack and its end is Xi (i=2~n), and the slot spacing on the winding rack is Y, then Xi=X1+Y / n*(i-1). By creating slots in this manner, a spiral groove with a pitch of Y can be obtained on each winding rack in one cycle. During winding, the conductive wire can be safely and securely placed into each slot. The slots also serve to hold the triangular conductive wire, preventing it from sliding back and forth and causing accuracy errors. Then, a battery cell is used to align the wound conductive wire, thus completing the precise alignment of the battery cell and the conductive wire.
[0031] Taking the 12-sided roller as an example, the specifications of the solar cells are 182.2×97.5-190 mm, the grid spacing is 0.956 mm, and a total of 12 winding racks are required. The racks are marked with laser markings from 1 to 12. The distance from the first triangular groove in the groove of the first post to the end is the reference distance X1, and the gap is Y=0.956 mm (grid spacing). There are a total of 200 triangular grooves. Then, the distance from the first triangular groove to the end of each subsequent winding rack is Xi=X1+Y / 12*(i-1), where 12 is the number of sides of the polygon and the total number of winding posts. The winding posts must be installed on the roller body in the order of 1-12. Finally, the magnetic suction device and the silicone pad are assembled on the roller body.
[0032] According to the numerical calculations based on the theory described above, the winding drum of this invention can completely wind the triangular conductive wire into the triangular groove of each winding rack in a spiral manner. However, due to errors in workpiece machining accuracy and assembly accuracy, there may be conductive wires that do not enter the groove in the actual process. In this case, we need to adjust the rack position to ensure that each triangular conductive wire can completely enter the triangular groove.
[0033] As shown in Figure 4, the winding drum of this utility model is directly connected to a DD motor to form a winding mechanism 10. In front of it is a wire laying mechanism 12, and above it is a wire pulling mechanism 11. After the conductive wire passes through the wire laying mechanism, it is grabbed by the cylinder jaws of the wire pulling mechanism. The wire pulling mechanism clamps the conductive wire and pulls it onto the drum, fixing the triangular conductive wire onto the drum. When the drum rotates to wind the wire, the linear motor of the wire laying mechanism moves along the drum axis at a corresponding speed. When the drum rotates one revolution, the linear motor advances one grid spacing of 0.956mm to form a coupling. When the required number of revolutions is completed, the winding ends, and then one end of the conductive wire is fixed. At this time, the jaws of the wire pulling mechanism clamp the conductive wire and release it from the drum.
[0034] Any aspects of this utility model not described in detail are well-known technologies to those skilled in the art.
[0035] Finally, it should be noted that the above specific embodiments are only used to illustrate the technical solution of this utility model and not to limit it. Although this utility model has been described in detail with reference to the embodiments, those skilled in the art should understand that modifications and equivalent substitutions can be made to the technical solution of this utility model without departing from the spirit and scope of the technical solution of this utility model, and all such modifications and substitutions should be covered within the scope of the claims of this utility model.
Claims
1. A polygonal integrated winding cylinder for conductive wires in a stacked-grid battery, characterized in that, The integrated winding cylinder includes a drum body, which is composed of two opposing rollers. Multiple winding racks are arranged between the two rollers, evenly distributed between them to form a regular polygon. Each winding rack has several grooves. The distance between the first groove and the end of the winding rack, counting from one end, satisfies the following condition: If the integrated winding cylinder has n winding racks, numbered sequentially from 1 to n, and the distance between the first groove of the first winding rack and its end is X1, the distance between the first groove of the i-th winding rack and its end is Xi, i = 2 to n, and the groove spacing on the winding rack is Y, then Xi = X1 + Y / n*(i-1).
2. The polygonal winding integral tube for conductive wires of a stacked grid battery as described in claim 1, characterized in that, Multiple support rods are installed between the two rollers, and the winding rack is supported on the support rods.
3. The polygonal winding integral tube for conductive wires of a stacked grid battery as described in claim 2, characterized in that, The support rod is provided with a mounting groove, and the winding rack is installed in the mounting groove.
4. The polygonal winding integral tube for conductive wires of a stacked grid battery as described in claim 1, characterized in that, The cross-section of the groove on the wire-wound rack is triangular.
5. The polygonal winding integral tube for conductive wires of a stacked grid battery as described in claim 1, characterized in that, The outer side of the roller is equipped with a cushioning pad.
6. The polygonal winding integral tube for conductive wires of a stacked grid battery as described in claim 1, characterized in that, A pull stud is installed on the outer side of the roller, and the position of the pull stud is matched with the mating mechanism on the winding mechanism on which the integrated winding cylinder is to be installed.
7. The polygonal winding integral tube for conductive wires of a stacked grid battery as described in claim 1, characterized in that, A magnetic attraction device is provided on the inner side of the roller body, which can attract the press.