Correction device of IBC battery string

Abstract

The utility model provides a correction device of an IBC battery string, which comprises a placing platform and a correction module, and support frames are vertically arranged on two sides of the placing platform; the correcting module comprises a lifting adjusting module, a translation adjusting module and a pressing module, the pressing module is arranged on the supporting frame through the lifting adjusting module, the pressing module comprises a top frame, a bridge frame, a plurality of supporting blocks and a plurality of pressing block units, the supporting blocks are arranged on a lower frame of the top frame at equal intervals, and the bridge frame is movably arranged in the top frame through a downward pressing driving part; the multiple sets of pressing block units are arranged on a lower bridge beam of the bridge frame, each set of pressing block unit comprises two lower pressing blocks and a heating module, the heating module is erected between the two lower pressing blocks, and the supporting blocks correspond to the pressing block units in number and are correspondingly located below the middle of each set of pressing blocks. By combining a new mode of temperature control softening and reverse micro-bending, the buckling deformation condition of the battery string is corrected, rigid impact and damage to a welding part are avoided, the correction effect is improved, and the adaptability is high.

Description

Technical Field

[0001] This utility model relates to the field of photovoltaic cell technology, and in particular to a correction device for IBC cell strings. Background Technology

[0002] IBC (Interdigitated Back Contact) cells, also known as full back contact cells, are widely used in the photovoltaic field due to their high conversion efficiency. IBC cells are strung together by welding ribbons. During the welding process, the ribbons need to be heated to melt the solder layer on their surface. However, after welding, the ribbons gradually cool and shrink, causing the cells to be pulled towards the welding surface, resulting in warping and deformation of the cells. This leads to a decrease in the flatness of the cell string, affecting module performance and reliability, and increasing the risk of subsequent cell cracking. Currently, the main method for straightening cell strings relies on simple mechanical pressure. For example, the existing patent publication number CN 118867035 A provides an IBC cell string straightening device, welding machine, and welding method. This patented technology solves the problem of cell string straightening to a certain extent. However, the method of straightening by directly bending in the reverse direction is prone to breakage at the welded part. The structure of the simultaneous suction and pressure straightening method is also more complex, and it has poor adaptability to straightening cells of different sizes.

[0003] Therefore, a more effective device is needed to address the potential problems of IBC battery string correction. Utility Model Content

[0004] The purpose of this invention is to provide a correction device for IBC battery strings. Combining a novel design of temperature-controlled softening and reverse micro-bending, it corrects the warping and deformation of the battery cells in the battery string, avoids the rigid impact and damage to the welded parts caused by direct mechanical bending, improves the correction effect, and has strong adaptability.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a correction device for an IBC battery string, comprising a placement platform and a correction module, wherein support frames are erected on both sides of the placement platform; the correction module comprises a lifting adjustment module, a translation adjustment module, and a pressure correction module, wherein the pressure correction module is mounted on the support frame via the lifting adjustment module, and the pressure correction module comprises a top frame, a bridge frame, multiple support blocks, and multiple sets of pressure block units, wherein the support blocks are arranged at equal intervals on the lower frame of the top frame, the bridge frame is movably mounted within the top frame via a downward driving component, and the multiple sets of pressure block units are arranged on the lower bridge of the bridge frame, wherein each set of pressure block units comprises two downward pressure blocks and a heating module, wherein the heating module is mounted between the two downward pressure blocks, the number of support blocks corresponds to the number of pressure block units, and the support blocks are located below the middle of each set of downward pressure blocks, wherein the surfaces of the support blocks and the downward pressure blocks that contact the battery string are planar.

[0006] As a further improvement of the present invention, the downward driving component is provided on the upper frame of the top frame, and a connecting block is provided on the upper bridge of the cable tray. The connecting block is connected to the downward driving component, and the downward driving component drives the cable tray to move up and down within the top frame.

[0007] As a further improvement of this utility model, the lower pressure block is provided with an upper guide hole and a lower guide hole. The lower bridge passes through the upper guide hole of the lower pressure block to connect all the lower pressure blocks in series. The lower guide hole of the lower pressure block is filled with a slide rail, and the heating module is connected in series between the lower pressure blocks.

[0008] As a further improvement of this utility model, the support block is slidably connected to the lower frame, and an adjusting spring is provided between adjacent support blocks; the lower pressure block is slidably connected to the lower bridge, and in each group of pressure block units, a synchronous spring is provided between the two lower pressure blocks, and a centering spring is provided between the heating module and the lower pressure block; the distance between the two lower pressure blocks in each group of pressure block units is equal, and the distance between the heating module and the lower pressure block in each group of pressure block units is equal.

[0009] As a further improvement of this utility model, it also includes a side pressure plate, which is movably disposed at both ends of the bridge frame by a lateral adjustment drive component. The side pressure plate includes an upper plate section, a middle leg section and a lower foot plate. The upper plate section is connected to the movable end of the lateral adjustment drive component and is located above the lower bridge. The middle leg section extends across the lower bridge towards the lower edge of the top frame. The lower foot plate is arranged parallel to the lower edge and is located on the same horizontal line as the adjusting spring.

[0010] As a further improvement of this utility model, the upper plate segment moves closer to or further away from the lower pressure block under the drive of the lateral adjustment drive component; the lower foot plate moves closer to or further away from the support block under the drive of the lateral adjustment drive component.

[0011] As a further improvement of the present invention, the lifting adjustment module includes a lifting drive component and a lifting frame. The two side frames of the top frame are provided with slots. The lifting frame is engaged with the slots and connected to the top frame. The slots and the lifting frame are slidably connected. The fixed end of the lifting drive component is located on the top of the support frame. The movable end of the lifting drive component is connected to the lifting frame and is used to drive the lifting frame and the top frame to perform lifting movements.

[0012] As a further improvement of this utility model, the top frame is provided with a connecting rod on its side, the fixed end of the translation adjustment module is located on one side of the lifting frame, the movable end of the translation adjustment module is connected to the connecting rod, and the translation adjustment module drives the top frame to move along the lifting frame.

[0013] As can be seen from the above technical solutions, the IBC battery string correction device of this utility model has at least the following advantages.

[0014] 1. The solder layer is heated to a softened state by the heating module, making the solder ductile. Then, the reverse bending amplitude is precisely controlled at 1%-3% to avoid the rigid impact of direct mechanical bending on the welded part, avoid excessive pressure, and reduce the risk of fracture caused by mechanical stress in the welded part. This is especially effective in addressing the problem that direct reverse bending may damage the solder joint in existing technologies.

[0015] 2. This utility model has strong versatility and consistency, and can be used to correct battery cells of different sizes. By adjusting the design of the spring, centering spring and synchronization spring, the spacing of each lower pressure block, support block and heating module can be adjusted synchronously to adapt to battery cells of different widths, which enhances the versatility and flexibility of the device and reduces production costs.

[0016] 3. The heating module of this utility model is a circulating heating system. The infrared temperature sensor monitors the temperature in real time, and the electric heater cycles on and off in the range of 180-240℃ to ensure that the solder layer is kept in a stable softened state, avoiding local overheating that could cause the solder to melt or the battery cell to be damaged by heat. It is energy-saving and efficient.

[0017] 4. This utility model achieves precise positioning and step-by-step operation through the linkage of the lifting adjustment module, the translation adjustment module, the pressing drive component, and the lateral adjustment drive component, further ensuring the safety and stability of the correction process. Attached Figure Description

[0018] Figure 1 This is a three-dimensional structural diagram of the correction device of this application.

[0019] Figure 2 This is a plan view of the correction device of this application.

[0020] Figure 3 This is a schematic diagram of the explosive disassembly of the correction device in this application.

[0021] Figure 4 for Figure 3 Enlarged diagram of point A in the middle.

[0022] Figure 5 for Figure 3 Enlarged diagram of point B in the middle. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be described in detail below with reference to the accompanying drawings and specific embodiments. It should also be noted that, for ease of description, only the parts relevant to this utility model are shown in the drawings, not the entire structure.

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

[0025] Reference Figures 1-3 This embodiment of an IBC battery string correction device includes a placement platform 100 and a correction module. Support frames 110 are erected on both sides of the placement platform. The correction module includes a lifting adjustment module 200, a translation adjustment module 300, and a pressure correction module 400. The pressure correction module 400 is mounted on the support frame 110 via the lifting adjustment module 200. The pressure correction module 400 includes a top frame 410, a cable tray 420, multiple support blocks 430, and multiple sets of pressure block units 440. The support blocks 430 are arranged at equal intervals on the lower frame 411 of the top frame 410. The cable tray 420 is movably mounted in the top frame 410 via a pressing drive component 412. The inner walls of the two side frames of the top frame 410 are longitudinally provided with sliding grooves 413. The two ends of the cable tray 420 are slidably connected in the sliding grooves 413. The pressing drive component 412 is used to drive the cable tray 420 to slide in the sliding grooves. Multiple sets of pressure block units 440 are arranged on the lower bridge 421 of the bridge 420. The multiple sets of pressure block units 440 are arranged side by side on the lower bridge 421 along the first horizontal direction, which is parallel to the length direction of the IBC battery string to be corrected. Each set of pressure block units 440 includes two lower pressure blocks 441 and a heating module 442. The heating module 442 is mounted between the two lower pressure blocks 441 and is located in the middle of the two lower pressure blocks 441. The number of support blocks 430 corresponds to the number of pressure block units 440, and the support blocks 430 are located in the middle and below the middle of each set of lower pressure blocks 441. The upper edges on both sides of the support blocks 430 and the lower edges on both sides of the lower pressure blocks 441 have arc-shaped corners, and the surfaces of the support blocks 430 and the lower pressure blocks 441 that contact the battery string are flat. This ensures that the contact surfaces are flat and that the edges of the support blocks 430 and the lower pressure blocks 441 do not scratch the battery cells when they contact the battery cells.

[0026] When straightening the battery string, the battery panel with the battery string is first placed flat on the placement platform. Multiple battery strings are arranged regularly. Each time it is pressed down, each pressure block unit 440 corresponds to one battery cell in the battery string. The pressure block unit 440 is aligned with the battery cell in the battery string below. The heating module 442 starts cyclic heating. When the heating module 442 pauses for the first time during the cyclic heating process, the lifting adjustment module 200 drives the top frame 410 to rise, so that the support block 430 presses against the lower surface of the battery cell. The pressing drive component 412 drives the bridge 420 to descend, so that the pressing block 441 presses down on both sides of the battery cell. When the battery cell is squeezed to the point that it bends in the opposite direction, the degree of bending is within the range of 1%-3% of the reverse warping. The heating module 442 stops working, and the welding material of the battery cell cools down and pulls the battery cell back to its original bending state. Due to the 1%-3% reverse bending amplitude of the heating correction, the battery cell returns to a horizontal state after natural cooling, thus completing the straightening of the battery string. After one battery string is calibrated, the pressure block unit 440 is moved to the next row of battery strings under the drive of the translation adjustment module 300, and the calibrating process is repeated. This solution calibrates the battery strings by temperature-controlled softening and reverse micro-bending, reducing the risk of welding breakage, avoiding over-calibration, and improving the calibration effect.

[0027] Specifically, the downward driving component 412 is located on the upper frame 414 of the top frame 410, and a connecting block 423 is provided on the upper bridge 422 of the cable tray 420. The connecting block 423 is connected to the downward driving component 412, and the downward driving component 412 drives the cable tray 420 to move up and down within the frame of the top frame 410. In this embodiment, the downward driving component 412 can be a lead screw motor, and the connecting block 423 is a lead screw nut component that matches the lead screw of the lead screw motor. When the lead screw motor is started, it drives the connecting block 423 to move up and down on the lead screw, thereby driving the cable tray 420 and the pressure block unit 400 on it to move up and down.

[0028] like Figure 4Each pressing block 441 has an upper guide hole 4411 and a lower guide hole 4412 at the same position. A lower bridge 421 passes through the upper guide hole 4411 of the pressing block 441, connecting all the pressing blocks 441 in series. A slide rail passes through the lower guide hole 4412 of the pressing block 441, and the heating module 442 is connected in series between the pressing blocks 441. The slide rail is a long straight slide rail that runs through all the pressing blocks 441, serving as a guide and connection. The heating module 442 includes an electric heater and an infrared temperature sensor. The electric heater is an infrared electric heater. The infrared temperature sensor senses and monitors the temperature, controls the infrared electric heater to cycle through the heating process, and shuts off the electric heater when the correction task conditions are met. In addition, regarding the distance setting between the electric heater and the battery cell, existing technologies such as laser ranging and eddy current sensing can be used to provide feedback and control the distance between the electric heater and the battery cell. Combined with a PID algorithm, the heater height can be adjusted. At the same time, a thermal expansion compensation module is integrated to maintain a constant distance accuracy of ±0.03mm, further ensuring uniform softening of the solder and avoiding thermal shock damage. This is only an additional supplement to illustrate that the distance between the heating module and the battery cell can be set according to the type of battery cell before the correction operation. This application does not elaborate on this point, which does not affect the realization of the complete technical effect of the battery string correction solution.

[0029] The lifting adjustment module 200 includes a lifting drive component 210 and a lifting frame 220. The outer walls of both sides of the top frame 410 have slots 415. The lifting frame 220 is engaged in the slots 415 and connected to the top frame 410. The slots 415 and the lifting frame 220 are slidably connected, meaning there is no vertical relative movement between the top frame 410 and the lifting frame 220. However, the top frame 410 can move horizontally relative to the lifting frame 220 under the drive of the translation adjustment module 300. The fixed end of the lifting drive component 210 is located on the top of the support frame 110, and the movable end of the lifting drive component 210 is connected to the lifting frame 220, used to drive the lifting frame 220 and the top frame 410 to perform lifting movements. A connecting rod 416 is provided on the side of the top frame 410. The fixed end of the translation adjustment module 300 is located on one side of the lifting frame 220, and the movable end of the translation adjustment module 300 is connected to the connecting rod 416. The translation adjustment module 300 drives the top frame 410 to move along the two side supports of the lifting frame 220. In this embodiment, the lifting drive component 210 can be an existing electric cylinder, lead screw motor module, or other lifting drive mechanism, and the translation adjustment module 300 can be an existing electric cylinder, lead screw motor module, or other translation linear drive mechanism. Existing mature components can be selected according to actual needs.

[0030] Furthermore, the support block 430 is slidably connected to the lower frame 411, and identical adjusting springs 431 are connected between adjacent support blocks 430. The lower pressure block 441 is slidably connected to the lower bridge 421. In each pressure block unit 440, identical synchronous springs 443 are connected between the two lower pressure blocks 441, and a central spring 444 is connected between the heating module 442 and the lower pressure block 441. That is, each pressure block unit 440 has two central springs 444, respectively located on both sides of the heating module 442, and the central springs 444 are sleeved on the outer ring of the slide rail. The distance between the two lower pressure blocks 441 in each pressure block unit 440 is equal, and the distance between the heating module 442 and the lower pressure block 441 in each pressure block unit 440 is equal. The support block 430 contacts the bottom of the battery cell, providing support and preventing the battery cell from sinking or experiencing uneven force during the correction process.

[0031] The IBC battery string correction device also includes side pressure plates 500, which are movably disposed at both ends of the bridge 420 via lateral adjustment drive components 510, as shown in the reference. Figure 5 The side pressure plate 500 includes an upper plate section 520, a middle leg section 530, and a lower foot plate 540. The upper plate section 520 is connected to the movable end of the lateral adjustment drive component 510 and is located above the lower bridge 421. The fixed end of the lateral adjustment drive component 510 is fixed to the top of the bridge frame 420. The middle leg section 530 extends across the lower bridge 421 towards the lower frame 411 of the top frame 410. The lower foot plate 540 is parallel to the lower frame 411 and is on the same horizontal line as the adjusting spring 431. Under the drive of the lateral adjustment drive component 510, the upper plate section 520 moves closer to or away from the lower pressure block 441, and the lower foot plate 540 moves closer to or away from the support block 430, also under the drive of the lateral adjustment drive component 510. The lateral adjustment drive component 510 can be an existing electric cylinder, a lead screw motor module, or other translational linear drive mechanism to drive the side pressure plate 500 to perform translational movement.

[0032] When correcting battery cells of different sizes, the spacing between the lower pressure block 441, the support block 430, and the heating module 442 can be adjusted in a timely manner. The lateral adjustment drive components 510 on both sides are activated to drive the side pressure plate 500 to move. The upper plate sections 520 of the side pressure plates 500 at both ends move inward to squeeze the lower pressure block 441. The synchronous springs 443 are subjected to the same pressure and contract synchronously, so that the spacing between the multiple lower pressure blocks 441 is shortened synchronously. Similarly, the heating module 442 is squeezed from both sides and the spacing changes synchronously. At the same time, the lower foot plate 540 of the side pressure plate 500... The linkage compression support block 430, and under the action of the adjusting spring 431, the spacing of all support blocks 430 synchronously shrinks, expanding the spacing between the lower pressure block 441, support blocks 430, and heating module 442. This can be achieved by synchronously adjusting the side pressure plate 500 to move outward to both sides, so that each spring automatically and synchronously increases the spacing between the lower pressure block 441, support blocks 430, and heating module 442 under the action of the restoring force. This allows for convenient adjustment of the spacing between the lower pressure block 441, support blocks 430, and heating module 442 to accommodate battery cells of different widths.

[0033] The above-mentioned IBC battery string correction device is used to correct the battery string. The steps include: placing the battery board with the battery string flat on the placement platform 100 with the welding surface facing upwards, the battery string is warped upwards, and multiple battery strings are arranged regularly. Each time it is pressed down, each pressure block unit 440 corresponds to one battery cell in the battery string. The pressure block unit 440 is aligned with the battery cell in the battery string below. The heating module 442 starts cyclic heating to avoid local overheating that could cause the solder to melt or the battery cell to be thermally damaged. It is energy-saving and efficient. When the heating module 442 pauses for the first time during the cyclic heating process, the lifting adjustment module 200 then drives the top frame 410 to rise, so that the support block 4 30. The top surface of the solar panel is lowered by the pressure drive component 412, which drives the bridge 420 to descend, causing the pressure block 441 to press down on both sides of the solar cell. When the solar cell is pressed to the point of reverse bending, the degree of bending is within the range of 1%-3%, preferably 2%. The control system will send a signal to the heating module 442 to stop working. After natural cooling, the welding ribbon shrinks and pulls, and the solar cell naturally returns to a horizontal state from reverse bending, completing the correction of the solar cell string. After completing the correction of one solar cell string, the pressure block unit 440 is moved to the next row of solar cells under the drive of the translation adjustment module 300, and the pressure correction steps are repeated.

[0034] The heating pause temperature condition during the cyclic heating process is 200℃-240℃. When the heating temperature reaches the pause temperature condition, the heating module stops heating. The temperature is monitored and dropped to 180℃ before heating is restarted. This heating and cooling process is repeated until the battery cell is bent in the opposite direction to the set degree. The cyclic heating ends and the heating module is turned off to allow it to cool naturally to room temperature. The heating module can pause heating at any temperature between 200℃ and 240℃. In specific embodiments, it can pause heating at any temperature between 210℃, 215℃, 220℃, 225℃, 230℃, 235℃, and 240℃. Due to the solid-liquid phase change characteristics of solder, the solidus temperature of common lead-free solder (such as SAC305) is 217℃ and the liquidus temperature is 220℃. The range of 200℃-240℃ ensures that the solder is in a "viscoplastic" state (the proportion of solid and liquid coexisting phases is about 15-30%), which can both ensure the solder flow and wetting (viscosity reduced to 0.1-0.5 Pa·s) and avoid the risk of overflow caused by complete melting.

[0035] The table below provides an example of the reverse bending amplitude.

[0036]

[0037] The table above shows that the 1%-3% reverse bending range is controllable and effective, and the 2% reverse bending range is the preferred value. While ensuring the correction effect, the stress / strain of key parts is controlled below 60% of the material safety threshold, achieving the best balance between correction efficiency and reliability.

[0038] The above embodiments are only used to illustrate the present utility model and are not intended to limit the technical solutions described in the present utility model. The understanding of this specification should be based on those skilled in the art. Although the present utility model has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still make modifications or equivalent substitutions to the present utility model. All technical solutions and improvements that do not depart from the spirit and scope of the present utility model should be covered within the scope of the claims of the present utility model.

Claims

1. A correction device for an IBC battery string, characterized in that: It includes a placement platform and a correction module, with support frames erected on both sides of the placement platform; The correction module includes a lifting adjustment module, a translation adjustment module, and a pressure adjustment module. The pressure adjustment module is mounted on the support frame via the lifting adjustment module. The pressure adjustment module includes a top frame, a bridge, multiple support blocks, and multiple sets of pressure block units. The support blocks are arranged at equal intervals on the lower edge of the top frame. The bridge is movably mounted within the top frame via a downward driving component. The multiple sets of pressure block units are arranged on the lower bridge of the bridge. Each set of pressure block units includes two lower pressure blocks and a heating module. The heating module is mounted between the two lower pressure blocks. The number of support blocks corresponds to the number of pressure block units, and the support blocks are located below the middle of each set of lower pressure blocks. The surfaces of the support blocks and the lower pressure blocks that contact the battery string are flat.

2. The correction device for IBC battery strings as described in claim 1, characterized in that: The downward driving component is located on the upper frame of the top frame, and a connecting block is provided on the upper bridge of the cable tray. The connecting block is connected to the downward driving component, and the downward driving component drives the cable tray to move up and down within the top frame.

3. The correction device for IBC battery strings as described in claim 1, characterized in that: The lower pressure block has an upper guide hole and a lower guide hole. The lower bridge passes through the upper guide hole of the lower pressure block to connect all the lower pressure blocks in series. The slide rail passes through the lower guide hole of the lower pressure block to connect the heating module between the lower pressure blocks.

4. The correction device for IBC battery strings as described in claim 1, characterized in that: The support block is slidably connected to the lower frame, and an adjusting spring is provided between adjacent support blocks; the lower pressure block is slidably connected to the lower bridge, and a synchronization spring is provided between two lower pressure blocks in each group of pressure block units, and a centering spring is provided between the heating module and the lower pressure block; the distance between the two lower pressure blocks in each group of pressure block units is equal, and the distance between the heating module and the lower pressure block in each group of pressure block units is equal.

5. The correction device for IBC battery strings as described in claim 4, characterized in that: It also includes side pressure plates, which are movably disposed at both ends of the bridge frame via a lateral adjustment drive component. The side pressure plate includes an upper plate section, a middle leg section, and a lower foot plate. The upper plate section is connected to the movable end of the lateral adjustment drive component and is located above the lower bridge. The middle leg section extends across the lower bridge towards the lower edge of the top frame. The lower foot plate is arranged parallel to the lower edge and is located on the same horizontal line as the adjusting spring.

6. The correction device for IBC battery strings as described in claim 5, characterized in that: The upper plate segment moves closer to or further away from the lower pressure block under the drive of the lateral adjustment drive component; the lower foot plate moves closer to or further away from the support block under the drive of the lateral adjustment drive component.

7. The correction device for IBC battery strings as described in claim 1, characterized in that: The lifting adjustment module includes a lifting drive component and a lifting frame. The top frame has slots on both sides. The lifting frame is connected to the top frame by the slots and the slots are slidably connected to the lifting frame. The fixed end of the lifting drive component is located on the top of the support frame, and the movable end of the lifting drive component is connected to the lifting frame, which is used to drive the lifting frame and the top frame to move up and down.

8. The correction device for IBC battery strings as described in claim 7, characterized in that: The top frame is provided with a connecting rod on its side. The fixed end of the translation adjustment module is located on one side of the lifting frame, and the movable end of the translation adjustment module is connected to the connecting rod. The translation adjustment module drives the top frame to move along the lifting frame.

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