Photovoltaic module welding detection device

Abstract

The utility model relates to a photovoltaic module welding detection device. Comprising a sensing device; the conveying mechanism is arranged on a photovoltaic module conveying path after a welding procedure; the disturbance equipment is used for applying physical disturbance to a welding area of the photovoltaic module under the condition that the photovoltaic module is detected by the sensing equipment; the disturbance equipment is connected with the sensing equipment; and the image processing equipment is used for acquiring image information of the welding area after the disturbance is applied. By adopting the device, the welding detection accuracy of the photovoltaic module can be improved.

Description

Technical Field

[0001] This application relates to the field of photovoltaic technology, and in particular to a photovoltaic module welding inspection device. Background Technology

[0002] With the gradual upgrading of photovoltaic module grid line technology, the density of grid lines in photovoltaic modules is also increasing, which can shorten the current transmission path and reduce lateral resistance loss. However, the reduction in grid line spacing will bring a series of problems. For example, the reduction in grid line spacing will lead to a reduction in the welding area, uneven distribution of contact pressure between the solder ribbon and the grid line, and easy to cause poor soldering.

[0003] In traditional technology, since there are a large number of solder joints in the welding area that need to be detected for poor solder joints, the welding area of ​​photovoltaic modules is usually inspected manually. Some poor solder joints are easy to miss. Therefore, the accuracy of detection is poor when using manual methods to detect poor solder joints. Utility Model Content

[0004] Therefore, it is necessary to provide a photovoltaic module welding inspection device that can improve the accuracy of photovoltaic module welding inspection in response to the above-mentioned technical problems.

[0005] Firstly, this application provides a photovoltaic module welding inspection device. It includes:

[0006] Sensing equipment; installed on the photovoltaic module conveying path after the welding process;

[0007] A disturbance device that applies physical disturbance to the welding area of ​​a photovoltaic module when the sensing device detects the photovoltaic module; the disturbance device is connected to the sensing device; and

[0008] An image processing device for acquiring image information of the welding area after a disturbance has been applied.

[0009] In one embodiment, the photovoltaic module is conveyed via a conveyor belt after welding; the disturbance device includes a vibration component attached to the underside of the conveyor belt.

[0010] In one embodiment, the vibration frequency range of the vibration component is 10Hz-50Hz.

[0011] In one embodiment, the vibration assembly includes at least two vibration sources with different vibration transmission directions.

[0012] In one embodiment, the vibration assembly includes at least two vibration sources with the same vibration transmission direction, and each vibration source has the same vibration frequency and initial phase.

[0013] In one embodiment, the sensing device includes a pressure sensing device disposed below the conveyor belt.

[0014] In one embodiment, the disturbance device includes a pneumatic assembly that applies disturbance to the welding area via pneumatic jetting.

[0015] In one embodiment, the pneumatic assembly includes a plurality of pneumatic nozzles; the jet direction of each pneumatic nozzle changes with the position of the photovoltaic assembly during the transport process.

[0016] In one embodiment, the device further includes:

[0017] When the image information indicates that there is a welding abnormality in the welding area, a sorting device for sorting the photovoltaic modules is used.

[0018] In one embodiment, an alarm device is also included that generates an alarm signal when the image information indicates that there is a welding abnormality in the welding area;

[0019] The sorting equipment is used to sort the photovoltaic modules upon receiving the alarm signal.

[0020] The aforementioned photovoltaic module welding inspection device includes sensors installed on the photovoltaic module conveying path after the welding process. These sensors monitor the conveying position of the photovoltaic modules in real time to ensure the smooth operation of subsequent welding inspection processes. A disturbance device is also included, which applies physical disturbance to the welding area of ​​the photovoltaic module when the sensors detect it, ensuring the welding area is fully covered by the applied disturbance. Finally, an image processing device is configured to acquire image information of the welding area after the disturbance is applied, determining the welding status of the photovoltaic module. Therefore, by employing this photovoltaic module welding inspection device, the accuracy of photovoltaic module welding inspection can be guaranteed while ensuring that all weld points in the photovoltaic module welding area are completely covered by disturbance. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of a photovoltaic module welding inspection device in one embodiment;

[0022] Figure 2 A diagram showing the position of the vibration component in one embodiment;

[0023] Figure 3 A diagram showing the location of the pressure sensing device in one embodiment;

[0024] Figure 4 A diagram showing the positional arrangement of pneumatic components in one embodiment;

[0025] Figure 5 This is a spray direction diagram of a pneumatic nozzle in one embodiment;

[0026] Figure 6 This is a spray direction diagram of the pneumatic nozzle in another embodiment;

[0027] Figure 7 This is a schematic diagram of the photovoltaic module welding inspection device in another embodiment;

[0028] Figure 8 This is a schematic diagram of the photovoltaic module welding inspection device in another embodiment;

[0029] Figure 9 This is a schematic diagram of the welding area of ​​a photovoltaic module in one embodiment before it is disturbed;

[0030] Figure 10 This is a schematic diagram of the welding area of ​​a photovoltaic module after it has been disturbed in one embodiment.

[0031] Reference numerals: 10-Sensing device; 11-Pressure sensing device; 20-Disturbance device; 21-Vibration component; 22-Pneumatic component; 221-Pneumatic nozzle; 222-Pneumatic nozzle; 223-Pneumatic nozzle; 30-Image processing device; 40-Sorting device; 50-Alarm device. Detailed Implementation

[0032] To facilitate understanding of this application, a more complete description will be provided below with reference to the accompanying drawings, which illustrate embodiments of the present application. However, the present application can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that the disclosure of this application will be thorough and complete.

[0033] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application.

[0034] Spatial relation terms such as “below,” “under,” “below,” “under,” “above,” “above,” etc., are used herein to describe the relationship between one element or feature shown in the figure and other elements or features. It should be understood that, in addition to the orientation shown in the figure, spatial relation terms also include different orientations of the device in use and operation. For example, if the device in the figure is flipped, the element or feature described as “below,” “under,” or “below” will be oriented “above” the other element or feature. Therefore, the exemplary terms “below” and “under” can include both above and below orientations. Furthermore, the device may also include other orientations (e.g., rotated 90 degrees or other orientations), and the spatial descriptive terms used herein will be interpreted accordingly.

[0035] It should be noted that when one element is considered to be "connected" to another element, it can be directly connected to the other element or connected to the other element through an intermediary element. Furthermore, in the following embodiments, "connection" should be understood as "electrical connection," "communication connection," etc., if there is transmission of electrical signals or data between the connected objects.

[0036] When used herein, the singular forms of “a,” “an,” and “the” may also include the plural forms unless the context clearly indicates otherwise. It should also be understood that the terms “comprising / including” or “having,” etc., specify the presence of the stated features, wholes, steps, operations, components, parts, or combinations thereof, but do not preclude the possibility of the presence or addition of one or more other features, wholes, steps, operations, components, parts, or combinations thereof. Meanwhile, the term “and / or” as used in this specification includes any and all combinations of the associated listed items.

[0037] As described in the background section, with the gradual upgrading of photovoltaic module grid line technology, the density of grid lines in photovoltaic modules is also increasing, which can shorten the current transmission path and reduce lateral resistance loss. However, the reduction in grid line spacing will bring a series of problems. For example, the reduction in grid line spacing will lead to a reduction in the welding area, uneven distribution of contact pressure between the solder ribbon and the grid line, and easy to cause poor soldering.

[0038] In traditional technology, since there are a large number of solder joints in the welding area that need to be detected for poor solder joints, the welding area of ​​photovoltaic modules is usually inspected manually. Some poor solder joints are easy to miss. Therefore, the accuracy of detection is poor when using manual methods to detect poor solder joints.

[0039] For the reasons mentioned above, such as Figure 1As shown, this application provides a photovoltaic module welding inspection device, including: a sensing device 10; a photovoltaic module conveying path disposed after the welding process; a disturbance device 20 that applies physical disturbance to the welding area of ​​the photovoltaic module when the sensing device 10 detects the photovoltaic module; the disturbance device 20 being connected to the sensing device 10; and an image processing device 30 for acquiring image information of the welding area after the disturbance is applied.

[0040] The sensing device 10 is a device capable of sensing and detecting specific physical quantities (such as light, heat, pressure, position, etc.) and converting them into electrical signals or other processable signals. In this embodiment, the sensing device 10 is installed on the conveying path after the welding process to monitor in real time whether the photovoltaic module has reached the designated position, ensuring accurate triggering of subsequent disturbance and detection processes. For example, the sensing device 10 may include a photoelectric sensor to detect changes in light to determine the position of the photovoltaic module; it may also include a proximity switch to determine whether the photovoltaic module has reached the designated position based on its movement path; or it may include a vision sensor (such as an industrial camera) to acquire images of the photovoltaic module's movement and determine whether the photovoltaic module has reached the designated position based on the acquired images. The welding process refers to the process of welding the solder strips and grid lines in the photovoltaic module. The photovoltaic module conveying path is the path used to transport the welded photovoltaic module from the welding station to the next process (such as lamination, framing, etc.).

[0041] The welding area refers to the area in the photovoltaic module where welding operations are performed. The disturbance device 20 refers to a device capable of applying physical force or energy (such as vibration, impact, pressure, etc.) to a target object, which can be controlled by programming. For example, the disturbance device 20 may include a vibration component, a pneumatic component, an ultrasonic generator, etc. The image processing device refers to the hardware and software system used to acquire, process, and analyze image data, typically including an industrial camera, lens, light source, image acquisition card, and image processing software. It can acquire image information of the interconnect-busbar welding area before and after disturbance, and then, based on a deep learning model, identify the solder strip offset and warping angle in the image, outputting the result of the cold weld location. Optionally, a combined virtual and real dataset containing images of normal solder joints and artificially simulated cold welds after physical disturbance can be used to train the AI ​​(Artificial Intelligence) analysis module in the image processing device to enhance its sensitivity to hidden defects. A photovoltaic module, also known as a solar panel, is a device that directly converts solar energy into electrical energy using the photovoltaic effect of semiconductor materials. It typically consists of multiple solar cells connected in series or parallel and encapsulated in a specific material.

[0042] Specifically, with the gradual upgrading of photovoltaic module grid line technology, the density of grid lines in photovoltaic modules is increasing, and the grid line spacing is decreasing. This leads to a reduction in the welding area and uneven distribution of contact pressure between the solder strip and the grid lines, which can easily cause cold solder joints. Therefore, it is necessary to detect the welding condition of the welding area. In this embodiment, a sensing device 10 is configured on the photovoltaic module conveying path after the welding process to monitor in real time whether the photovoltaic module has reached the designated position, ensuring the accurate triggering of subsequent disturbance and detection processes. After detecting that the photovoltaic module has reached the designated position, the disturbance device 20 can apply physical disturbance to the welding area to stimulate potential welding defects (such as cold solder joints or cracks). The image processing device will collect image information of the welding area before and after the disturbance, and analyze the image features through image comparison to determine whether the welding area includes cold solder joints. Optionally, the positions of the disturbance device 20 and the image processing device are not fixed and do not necessarily have to be set on the photovoltaic module conveying path. Figure 1 This is just one possible setup. The positions of the disturbance device 20 and the image processing device can be flexibly set according to the actual situation, as long as the disturbance device 20 can disturb the photovoltaic module and the image processing device can collect image information of the welding area before and after the disturbance.

[0043] The aforementioned photovoltaic module welding inspection device includes a sensing device 10 installed on the photovoltaic module conveying path after the welding process. This sensing device can monitor the conveying position of the photovoltaic module in real time to ensure the normal operation of subsequent welding inspection processes. It also includes a disturbance device 20, which applies physical disturbance to the welding area of ​​the photovoltaic module when the sensing device 10 detects the module, ensuring that the welding area is fully covered by the applied physical disturbance. Finally, it includes an image processing device that can acquire image information of the welding area after the disturbance is applied to determine the welding status of the photovoltaic module. Therefore, by using the aforementioned photovoltaic module welding inspection device, the accuracy of photovoltaic module welding inspection can be guaranteed while ensuring that all weld points in the photovoltaic module welding area are completely covered by disturbance.

[0044] In one embodiment, such as Figure 2 As shown, the photovoltaic modules are conveyed via a conveyor belt after welding; the disturbance device 20 includes a vibration component 21 attached to the underside of the conveyor belt.

[0045] The conveyor belt is a continuous motion device used for material transport. In industrial production, the conveyor belt can run at different speeds and directions according to different production needs, transporting materials from one workstation to another, realizing automated production processes and improving production efficiency. The vibration component 21 is the core component in the agitation device 20 that generates vibration, typically consisting of a vibration motor, vibration springs, and a vibration table. The vibration motor provides power, causing the vibration table to vibrate at a certain frequency and amplitude. Through contact with the conveyor belt, the vibration is transmitted to the photovoltaic modules on the conveyor belt. The vibration parameters of the vibration component 21 (such as frequency, amplitude, and vibration direction) can be adjusted according to different process requirements to achieve different processing effects on the photovoltaic modules.

[0046] Specifically, after welding, the photovoltaic modules are conveyed to the next process via a conveyor belt. Before being conveyed to the next process, the welding condition of the photovoltaic modules needs to be inspected. In this embodiment, the photovoltaic modules are physically disturbed by a vibration component 21 attached to the bottom of the conveyor belt. That is, by attaching to the conveyor belt, the vibration is transmitted to the photovoltaic modules on the conveyor belt, thereby stimulating potential welding defects (such as cold solder joints or cracks) in the photovoltaic modules.

[0047] In this embodiment, the non-contact disturbance design ensures the accuracy of welding inspection without causing mechanical damage to the photovoltaic module. Furthermore, the vibration component 21 replaces manual disturbance, thereby improving inspection efficiency.

[0048] In one embodiment, the vibration frequency range of the vibration component 21 is 10Hz-50Hz.

[0049] The vibration frequency of the vibration component 21 refers to the number of times the vibration component 21 completes periodic vibrations per unit time.

[0050] Specifically, the vibration frequency range of the vibration component 21 is set to 10Hz-50Hz. On the one hand, this vibration frequency range is the same as or close to the natural frequency of the conveyor belt, which can produce resonance, increase the amplitude of the conveyor belt, and thus improve the disturbance effect of physical disturbance. On the other hand, this vibration frequency is synchronized with the conveying speed of the photovoltaic module, which can ensure that the vibration effect is uniformly applied to the photovoltaic module. For example, the vibration frequency of the vibration component 21 can be 10Hz, in which case the conveying speed of the conveyor belt is 1 m / s, and the vibration frequency can be synchronized with the conveying speed of the photovoltaic module, ensuring that the vibration effect is uniformly applied to the photovoltaic module. The vibration frequency of the vibration component 21 can also be 20Hz, in which case the conveying speed of the conveyor belt is 2 m / s, and the vibration frequency can be synchronized with the conveying speed of the photovoltaic module, ensuring that the vibration effect is uniformly applied to the photovoltaic module. Optionally, the amplitude range of the vibration component 21 can be set to 0.1mm-0.5mm to match the vibration of the conveyor belt. For example, the amplitude of the vibration component 21 can be 0.1mm, 0.2mm, 0.3mm, etc.

[0051] In this embodiment, the vibration frequency range of the vibration component 21 is set to 10Hz-50Hz. On the one hand, this vibration frequency range is the same as or close to the natural frequency of the conveyor belt, which can produce resonance and increase the amplitude of the conveyor belt, thereby improving the disturbance effect of physical disturbance. On the other hand, the vibration frequency is synchronized with the transmission speed of the photovoltaic module, which can ensure that the vibration effect is uniformly applied to the photovoltaic module.

[0052] In one embodiment, the vibration assembly 21 includes at least two vibration sources with different vibration transmission directions.

[0053] Among them, the vibration source refers to the object or system that generates vibration, which converts energy into vibration through mechanical, electromagnetic, fluid or other means.

[0054] Specifically, to improve the physical disturbance effect of the vibration component 21 on the photovoltaic module, at least two vibration sources with different vibration transmission directions can be set. On the one hand, the vibration waves from multiple vibration sources (such as vertical + horizontal or vertical + inclined) are superimposed in space to form a composite vibration trajectory, which can significantly increase the amplitude of the object. On the other hand, vibration waves in different directions form standing waves or traveling waves on the surface of the object, and the energy is distributed more evenly in space, reducing energy loss. For example, traditional vertical vibration may cause the object to slip on the conveyor belt, while horizontal vibration can provide additional driving force, making the object move more stably with the conveyor belt.

[0055] In one embodiment, the vibration assembly 21 includes at least two vibration sources with the same vibration transmission direction, and each vibration source has the same vibration frequency and initial phase.

[0056] Specifically, the same initial phase ensures that all vibration sources vibrate synchronously at startup, avoiding energy cancellation due to phase difference. Furthermore, in regions with the same vibration transmission direction, the superposition of vibration waves follows the principle of linear superposition, and the amplitude and energy are directly added. Therefore, when the vibration component 21 includes at least two vibration sources with the same vibration transmission direction and the vibration frequency and initial phase of each vibration source are the same, the vibration effect can be directly improved, ensuring the excitation effect of potential welding defects.

[0057] In one embodiment, such as Figure 3 As shown, the sensing device 10 includes a pressure sensing device 11 disposed below the conveyor belt.

[0058] Among them, the pressure sensing device 11 can convert the pressure signal of gas or liquid into a measurable electrical signal, thereby realizing accurate monitoring and control of pressure.

[0059] Specifically, the sensing device 10 may include a pressure sensing device 11, which is set at a designated position below the conveyor belt. When the photovoltaic module moves to the designated position, the pressure sensing device 11 will detect the pressure signal corresponding to the photovoltaic module, thereby realizing accurate detection of the position of the photovoltaic module.

[0060] In one embodiment, such as Figure 4 As shown, the disturbance device 20 includes a pneumatic assembly 22 that applies disturbance to the welding area by pneumatic spraying.

[0061] The pneumatic assembly 22 is a combination of components or devices that use compressed air as the working medium to achieve a specific function. In the disturbance device 20, the pneumatic assembly 22 mainly includes an air source (such as an air compressor), pneumatic actuators (such as cylinders, pneumatic motors, etc., which may be used to drive the mechanism that generates disturbance in the disturbance device 20), and pneumatic control elements (such as solenoid valves, pressure regulating valves, etc., used to control the flow rate, pressure, and direction of the gas). These pneumatic components work together to enable the pneumatic jet to apply disturbance to the welding area according to preset parameters.

[0062] Specifically, pneumatic jetting is a technology that uses compressed air as a power source to propel gas at high speed. The pneumatic assembly 22 typically consists of an air source, pneumatic actuators (such as cylinders), and pneumatic control elements (such as solenoid valves and pressure regulating valves). The air source provides stable compressed air, the pneumatic actuators convert the energy of the compressed air into mechanical energy, driving the jetting device to generate a high-speed airflow, and the pneumatic control elements precisely control the gas pressure, flow rate, and jet direction. When the pneumatic assembly 22 applies pneumatic jetting to the welding area, the resulting airflow can disturb the photovoltaic module, thereby triggering potential welding defects. For example, the pneumatic assembly 22 can be designed as an array of nozzles with a pressure range of 0.1 MPa to 0.3 MPa, which can be adaptive to different weld strip sizes.

[0063] In this embodiment, the non-contact disturbance design of the pneumatic component 22 is used to apply disturbance to the welding area. On the one hand, the accuracy of welding inspection can be guaranteed without mechanical damage to the photovoltaic module. On the other hand, the inspection efficiency can be improved by replacing manual disturbance with the vibration component 21.

[0064] In one embodiment, the disturbance component may further include a vibration component 21 and a pneumatic component 22, which, through the synergistic effect of the vibration component 21 and the pneumatic component 22, improve the disturbance effect on the photovoltaic module.

[0065] In one embodiment, such as Figure 5 As shown, the pneumatic assembly 22 includes multiple pneumatic nozzles; the jet direction of each pneumatic nozzle changes with the position of the photovoltaic module during the transmission process.

[0066] The pneumatic nozzle is a key component of the pneumatic assembly 22. It is a device that can eject compressed air in a specific shape and speed. Through its internal airflow channel design, it enables the compressed air to form an airflow with a certain direction, speed, and distribution pattern when ejected.

[0067] Specifically, to ensure the aerodynamic effect of the pneumatic component 22, it can be configured to include multiple pneumatic nozzles, which pneumatically spray the photovoltaic module. Optionally, the jet direction of each pneumatic nozzle can change according to the position change of the photovoltaic module during the transport process, for example, as... Figure 5 As shown, when the photovoltaic module moves to point a, the jet direction of pneumatic nozzle 221 is shifted to the right, the jet direction of pneumatic nozzle 222 is perpendicular to the conveyor belt, and the jet direction of pneumatic nozzle 223 is shifted to the left; as Figure 6As shown, when the photovoltaic module moves to point b, the jet direction of pneumatic nozzles 221, 222, and 223 is all shifted to the right, but the angle of the shift to the right is slightly different.

[0068] In this embodiment, multiple pneumatic nozzles are provided, and the jet direction of each pneumatic nozzle changes with the position of the photovoltaic module during the transmission process. The jet direction can be flexibly changed as the photovoltaic module moves, thereby ensuring the disturbance effect of the pneumatic component 22 on the photovoltaic module.

[0069] In one embodiment, such as Figure 7 As shown, the photovoltaic module welding inspection device also includes a sorting device 40 for sorting photovoltaic modules when the image information indicates that there is a welding abnormality in the welding area.

[0070] Among them, the sorting equipment 40 is a device used to classify and separate products of different quality grades according to preset standards or conditions.

[0071] Specifically, in the photovoltaic module welding inspection, when a welding abnormality is detected in the welding area, the sorting equipment 40 will separate the unqualified photovoltaic module from the qualified products for further processing, such as rework, repair or scrapping, so as to prevent the unqualified photovoltaic module from being sent to the lamination process and causing unnecessary waste of resources.

[0072] In one embodiment, such as Figure 8 As shown, the photovoltaic module welding inspection device also includes an alarm device 50 that generates an alarm signal when an abnormality is found in the welding area as indicated by the image information; and a sorting device 40 that sorts the photovoltaic modules upon receiving the alarm signal.

[0073] The alarm device 50 is a component of the welding inspection apparatus that generates an alarm signal when a welding abnormality is detected in the welding area. The alarm signal can be presented in the form of sound, light, or other means to remind operators or relevant systems to take timely measures.

[0074] Specifically, the photovoltaic module welding inspection device also includes an alarm device 50, which can generate an alarm signal when the image information indicates that there is a welding abnormality in the welding area. Upon receiving the alarm signal, the sorting device 40 can sort the photovoltaic module.

[0075] In this embodiment, the photovoltaic module welding inspection device also includes an alarm device 50. The sorting device 40 only sorts the photovoltaic module when it receives an alarm signal generated by the alarm device 50, which can reduce unnecessary costs.

[0076] In one embodiment, a photovoltaic module welding inspection device is also provided, which adds a disturbance device after the welding process to simulate the effect of manual manipulation and triggers all bright spots 100% to expose the deformation (skew / lift) of the poor solder joints due to weak mechanical connection, and then captures the abnormal features by line scanning with an image processing device.

[0077] In one specific embodiment, the disturbance device may include a vibration component or a pneumatic component. Specifically, the vibration component may be a piezoelectric ceramic vibrator integrated below the conveyor belt. Optionally, the vibration mode (e.g., frequency sweep) can be controlled by an algorithm to cover different resonance points. The pneumatic component may specifically include an array of airflow nozzles controlled by a precision solenoid valve, positioned 0.5cm-1cm above the welding strip for targeted pulse purging, avoiding physical contact damage.

[0078] In an optional embodiment, the synchronous control logic of the photovoltaic module welding inspection device may include:

[0079] ① By triggering a disturbance action through sensors, the photovoltaic module is ensured to start precisely when it moves to the designated position of the detection station, such as... Figure 9 The image shown is a schematic diagram of the photovoltaic module before it was disturbed. Figure 10 The diagram shows a photovoltaic module after it has been disturbed. Point c represents the change in the welding area of ​​the photovoltaic module after the disturbance, indicating that this point is a poor solder joint.

[0080] ②The image processing results are linked to the sorting robotic arm (sorting equipment) to realize the automatic removal of defective products from the production line.

[0081] The photovoltaic module welding inspection device described above can achieve at least the following beneficial effects:

[0082] 1. Dynamic Defect Excitation: By controlling physical disturbances, the bottleneck of static detection is overcome, and latent defects are transformed into explicit deformations.

[0083] 2. Full-process automation: Replaces manual intervention and is compatible with the pace of high-speed production lines (such as matching a production line cycle of 60 seconds per piece).

[0084] 3. Improved accuracy of composite detection: The AI ​​analysis module is optimized for features after disturbance, increasing the detection rate of cold solder joints from <95% to >99.9%.

[0085] Example effect verification:

[0086] In a production line test at a photovoltaic company, 3,000 OBB (Zero Busbar Module) modules were tested, with the disturbance parameters set to 20Hz vibration + 0.2MPa air jet.

[0087] The results showed that the detection rate of poor solder joints was 99.6% (only one case was missed during manual re-inspection, which was a very small edge defect); the misjudgment rate was ≤0.3%; the impact on production capacity was that the total inspection time was ≤4 seconds / piece, and the production line speed decreased by <2%.

[0088] 1. Fully automated coverage inspection: The disturbance equipment achieves 100% dynamic excitation of solder joints, eliminating blind spots in manual sampling (coverage rate increased from <30% to 100%).

[0089] 2. Standardized cold solder joint activation: Precisely control disturbance parameters (such as frequency, amplitude, and duration) to uniformly activate the deformation of cold solder joints, eliminating subjective errors of human operation (improving detection consistency by >80%);

[0090] 3. Enhanced Dynamic Defect Visualization: By using mechanical disturbances to induce quantifiable physical deformations in hidden solder joints (such as warpage angle ≥3° and offset 20.5mm), the image recognition accuracy is improved from <90% in traditional methods to ≥99.5%.

[0091] 4. High-density grid line adaptability: The innovative perturbation algorithm (such as partitioned gradient force application) is compatible with 0B8 high-density bright dots (spacing <0.3mm), overcoming the detection failure problem caused by visual occlusion in traditional technologies.

[0092] 5. Production line efficiency compatibility: The disturbance-detection linkage control module is synchronized with the production line speed (cycle time < 60 seconds / piece), detection time < 3 seconds / component, and production capacity loss is negligible (compared to the time waste caused by traditional sampling inspection, the overall efficiency is improved by 20%+).

[0093] 6. Non-destructive testing guarantee: Non-contact disturbance design (such as pneumatic pulse, ultrasonic excitation) ensures no mechanical damage at normal points, with a yield rate of >99.9%.

[0094] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this application.

[0095] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this application should be determined by the appended claims.

Claims

1. A photovoltaic module welding inspection device, characterized in that, include: Sensing devices; It is installed on the photovoltaic module conveying path after the welding process; A disturbance device that applies physical disturbance to the welding area of ​​a photovoltaic module when the sensing device detects the photovoltaic module; the disturbance device is connected to the sensing device. as well as An image processing device for acquiring image information of the welding area after a disturbance has been applied.

2. The photovoltaic module welding inspection device according to claim 1, characterized in that, The photovoltaic modules are conveyed via a conveyor belt after welding; the disturbance device includes a vibration component attached to the underside of the conveyor belt.

3. The photovoltaic module welding inspection device according to claim 2, characterized in that, The vibration frequency range of the vibration component is 10Hz-50Hz.

4. The photovoltaic module welding inspection device according to claim 2, characterized in that, The vibration assembly includes at least two vibration sources with different vibration transmission directions.

5. The photovoltaic module welding inspection device according to claim 2, characterized in that, The vibration assembly includes at least two vibration sources with the same vibration transmission direction, and each vibration source has the same vibration frequency and initial phase.

6. The photovoltaic module welding inspection device according to claim 2, characterized in that, The sensing device includes a pressure sensing device disposed below the conveyor belt.

7. The photovoltaic module welding inspection device according to claim 1, characterized in that, The disturbance device includes a pneumatic assembly that applies disturbance to the welding area via pneumatic jetting.

8. The photovoltaic module welding inspection device according to claim 7, characterized in that, The pneumatic assembly includes multiple pneumatic nozzles; the jet direction of each pneumatic nozzle changes according to the position of the photovoltaic assembly during the transmission process.

9. The photovoltaic module welding inspection device according to any one of claims 1 to 8, characterized in that, The device further includes: When the image information indicates that there is a welding abnormality in the welding area, a sorting device for sorting the photovoltaic modules is used.

10. The photovoltaic module welding inspection device according to claim 9, characterized in that, It also includes an alarm device that generates an alarm signal when the image information indicates that there is a welding abnormality in the welding area; The sorting equipment is used to sort the photovoltaic modules upon receiving the alarm signal.

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