Auxiliary device for welding and shaping junction box

Abstract

The utility model relates to the technical field of junction box processing, in particular to a junction box welding shaping auxiliary device which comprises a machine frame, an air blower fixedly arranged on the surface of the machine frame, a communicating pipe inserted into the top end of the air blower, a three-way pipe inserted into the side wall of the machine frame, and a sliding rail fixedly arranged on the side wall, close to the upper portion of the three-way pipe, of the machine frame. A sliding seat is movably connected to the side wall of the sliding rail, and two first electric push rods are fixedly arranged on the side wall of the sliding seat; compared with a traditional junction box welding shaping auxiliary device, the first support and the metal pipe are matched to improve the mounting and positioning precision of the metal pipe, the sliding rail is started, and the first electric push rod and the second electric push rod can drive the metal pipe to synchronously move along with the welding head; wind power can be generated by starting the air blower and sprayed out through the communicating pipe, the three-way pipe, the plastic pipe and the metal pipe, so that the junction box welded junction and the welding head are blown, cooling and solidification of the welded junction are accelerated, and the quality and efficiency of junction box welding shaping are improved.

Description

Technical Field

[0001] This utility model relates to the field of junction box processing technology, and in particular to a junction box welding and shaping auxiliary device. Background Technology

[0002] Junction boxes are crucial electrical connection components in photovoltaic systems. They are used to connect photovoltaic modules to external circuits, protect internal circuits, and ensure stable power transmission. Junction boxes typically consist of a box body, connectors, diodes, etc. During the production process, junction boxes usually require welding and shaping using junction box welding equipment.

[0003] Currently, junction box welding issues have consistently been a major source of customer complaints in the photovoltaic module industry, with the shortest turnaround time. Junction boxes affect the power generation of the entire photovoltaic array, negatively impacting customer experience and damaging the company's brand image. Junction box welding is currently categorized into molding soldering, tin-laying soldering, and thermoforming soldering. Industry research indicates that molding soldering is the most reliable method, exhibiting the lowest rate of incomplete soldering. Therefore, the industry is currently promoting molding soldering for junction boxes. However, the quality of junction box welding affects production line cycle time and increases rework material and labor costs.

[0004] Existing junction box welding shaping auxiliary devices generate high temperatures during use, which may cause the junction box weld joints to melt. After welding, some weld joints may not be completely solidified, which may cause deformation of the welded area, thus affecting the welding quality of the junction box. At the same time, allowing the junction box to cool statically affects the efficiency of the junction box welding process. Utility Model Content

[0005] To overcome the problems of existing junction box welding shaping auxiliary devices, which may cause the junction box weld joint to melt due to the high temperature generated during welding, and the weld joint to deform if it is not completely solidified after welding, thus affecting the welding quality of the junction box, and the junction box processing efficiency due to static cooling.

[0006] The technical solution of this utility model is as follows: a junction box welding and shaping auxiliary device, including a frame, a blower fixed on the surface of the frame, a connecting pipe inserted into the top of the blower, a T-pipe inserted into the side wall of the frame, a slide rail fixed on the side wall of the frame near the T-pipe, a sliding seat movably connected to the side wall of the slide rail, two first electric actuators fixed on the side wall of the sliding seat, a first mounting seat fixed at the output end of each of the two first electric actuators, a second electric actuator fixed on the side wall of each of the first mounting seats, a second mounting seat fixed at the output end of each of the second electric actuators, a welding head fixed at the bottom end of each of the second mounting seats, a first bracket fixed on the side wall of each of the second mounting seats, a metal tube inserted into the end of each first bracket near the welding head, and a plastic tube inserted into the top end of each metal tube.

[0007] Furthermore, one end of the three-way pipe passes through the frame and connects to the other end of the connecting pipe, while the other two ends of the connecting pipe are connected to the plastic pipe, thereby improving the stability of the air intake.

[0008] Furthermore, the first support and the metal tubes are symmetrically distributed, the bottom ends of the metal tubes are all arc-shaped, and the bottom ends of the metal tubes are threaded with nozzles. The nozzles are directly opposite the bottom end of the welding head, which improves the stability of the gas output.

[0009] Furthermore, each of the two first brackets has a first slot on its surface, through which the metal tube passes in sequence, improving the convenience of installing and positioning the metal tube.

[0010] Furthermore, two second brackets are fixed on the side walls of the two second mounting bases near the metal tube, and the surfaces of the second brackets are provided with second slots for the metal tube to be inserted, which improves the overall stability of the metal tube.

[0011] Furthermore, a groove is provided at the end of the second support. The groove is L-shaped and extends through the top of the second support. The plastic tube is slidably connected in the middle of the groove, which improves the stability of the plastic tube's movement.

[0012] Furthermore, a filter is inserted into the input end of the blower side wall, and the middle of the filter is filled with activated carbon filter cotton, which improves the safety of the purified air.

[0013] Furthermore, a limiting seat is fixed on the surface of the frame near the two welding heads, and a groove is provided in the middle of the limiting seat for the junction box to be engaged.

[0014] The beneficial effects of this utility model are:

[0015] Compared to traditional junction box welding shaping auxiliary devices, this device improves the accuracy of metal tube installation and positioning by using a first bracket and a metal tube in conjunction. Activating the slide rail, first electric actuator, and second electric actuator allows the metal tube to move synchronously with the welding head. Activating the blower generates airflow that is ejected through the connecting pipe, tee pipe, plastic tube, and metal tube, thus cleaning the junction box weld joint and welding head, accelerating weld cooling and solidification, and improving the quality and efficiency of junction box welding shaping. Secondly, the device incorporates a second bracket, a second slot, and a slide groove. The second slot allows the metal tube to be inserted, improving the overall stability of the metal tube. The external dimensions of the plastic tube are adapted to the internal dimensions of the slide groove, enhancing the stability and orderliness of the plastic tube's movement. Attached Figure Description

[0016] Figure 1 The diagram shown is an overall structural representation of the junction box welding and shaping auxiliary device of this utility model. Figure 1 ;

[0017] Figure 2The diagram shown is a schematic representation of the overall structure of this utility model. Figure 2 ;

[0018] Figure 3 The diagram shown is a schematic representation of the structure of the second mounting base of this utility model.

[0019] Figure 4 The diagram shown is a schematic representation of the metal tube structure of this utility model.

[0020] Figure 5 The diagram shown is a schematic diagram of the second support structure of this utility model.

[0021] Explanation of reference numerals in the attached drawings: 1. Frame; 2. Blower; 3. Connecting pipe; 4. T-joint; 5. Slide rail; 6. Sliding seat; 7. First electric actuator; 8. First mounting base; 9. Second electric actuator; 10. Second mounting base; 11. First bracket; 12. Welding head; 13. Metal pipe; 14. Plastic pipe; 15. Limiting seat; 16. Second bracket; 17. Nozzle; 18. First slot; 19. Second slot; 20. Slide groove; 21. Filter. Detailed Implementation

[0022] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0023] Among the currently discovered feasible technologies, the following are described:

[0024] Against the backdrop of increasing global demand for clean energy, photovoltaic power generation, as a sustainable energy form, has been widely applied and developed. As a key component for the electrical connection of photovoltaic modules, the welding quality of photovoltaic junction boxes directly affects the performance and service life of photovoltaic modules. Therefore, high-performance photovoltaic junction box welding equipment is crucial for ensuring the quality and reliability of photovoltaic modules.

[0025] The frame is the basic framework of the entire welding equipment. It is usually made of high-strength steel by welding or casting, and has sufficient strength and rigidity to ensure the stability of the equipment during operation. The support structure is used to install and fix various functional components, such as welding heads, conveying mechanisms, positioning fixtures, etc., to ensure their relative positional accuracy during operation.

[0026] The conveying mechanism is responsible for transporting photovoltaic junction boxes and photovoltaic modules to the welding station. Common conveying methods include belt conveyor, chain conveyor, and robotic arm handling. Belt conveyor is characterized by smooth operation and low noise, and is suitable for light load and continuous conveying. Chain conveyor has the advantages of strong load-bearing capacity and accurate transmission, and is suitable for conveying heavier workpieces. Robotic arm handling can achieve precise positioning and flexible gripping, and can meet the conveying needs of photovoltaic junction boxes and modules of different specifications and shapes.

[0027] Positioning fixtures are used to accurately fix photovoltaic junction boxes and photovoltaic modules, ensuring the accuracy of welding positions. Positioning fixtures are usually pneumatically or hydraulically driven, and achieve precise positioning of workpieces through structures such as positioning pins and positioning blocks. At the same time, the fixtures also have a certain degree of self-adaptability, which can adapt to photovoltaic junction boxes and modules of different specifications and shapes, improving the versatility of the equipment.

[0028] The power supply system provides the electrical energy required for the welding equipment. Depending on the welding process, the type of power supply also varies. Resistance welding usually uses a low-voltage, high-current transformer power supply; laser welding requires a dedicated laser power supply that can provide a high-energy-density laser beam. The power supply system also includes a power control module, which is used to adjust the output parameters of the power supply, such as voltage, current, and power, to meet the requirements of different welding processes.

[0029] Sensor systems are used to monitor various parameters in the welding process in real time, such as welding temperature, pressure, current, and voltage, as well as the operating status of the equipment, such as conveying speed, positioning accuracy, and component failures. Common sensors include temperature sensors, pressure sensors, current sensors, voltage sensors, and proximity switches. The sensors feed back the monitored signals to the control system, which analyzes and processes them according to preset parameters and algorithms, and adjusts the operating status of the equipment in a timely manner to ensure the stability of the welding process and the reliability of the welding quality.

[0030] The welding head is a key component for achieving welding, and its structure and performance directly affect the welding quality. Depending on the welding process, welding heads come in various types. Resistance welding heads typically consist of electrodes, electrode arms, and conductive blocks; the electrodes are in direct contact with the workpiece, and welding is achieved through resistance heat generated by the current. Laser welding heads, on the other hand, include a laser focusing lens, a reflector, and a protective gas nozzle, which focus the laser beam onto the welding area, melting the material to achieve welding.

[0031] According to the preset welding process parameters, the welding system begins operation. Taking resistance welding as an example, the electrodes of the welding head are in close contact with the welding parts of the photovoltaic junction box and photovoltaic module. The power system provides low voltage and high current, which generates resistance heat at the welding part, heating the material to a molten state and forming a weld joint. During the welding process, sensors monitor parameters such as welding current, voltage, and temperature in real time and feed the data back to the control system. The control system adjusts the welding process in real time according to the preset parameter range to ensure the stability of the welding quality.

[0032] Please refer to Figures 1-5A junction box welding and shaping auxiliary device includes a frame 1 for support and limiting. A blower 2 is bolted to the surface of the frame 1 to generate airflow. A connecting pipe 3 is inserted into the top of the blower 2. A T-shaped pipe 4 is inserted into the side wall of the frame 1 for diverting flow. One end of the T-shaped pipe 4 passes through the frame 1 and connects to the other end of the connecting pipe 3. A slide rail 5 is bolted to the side wall of the frame 1 near the T-shaped pipe 4. A sliding seat 6 is movably connected to the side wall of the slide rail 5. Activating the slide rail 5 can drive the sliding seat 6 to move water. For horizontal movement, two first electric actuators 7 are bolted to the side wall of the sliding seat 6. The output ends of both first electric actuators 7 are bolted to first mounting seats 8. The two first mounting seats 8 are symmetrically distributed for support and limitation. Second electric actuators 9 are bolted to the side wall of each first mounting seat 8. Activating the first electric actuators 7 causes the second electric actuators 9 to move laterally. Second mounting seats 10 are bolted to the output ends of the second electric actuators 9. Welding heads 12 are bolted to the bottom ends of the second mounting seats 10. The frame 1 is fixed near the surfaces of the two welding heads 12. A limiting seat 15 is provided, with a groove in the middle for the junction box to engage, improving the convenience of welding positioning. Activating the second electric actuator 9 moves the second mounting base 10 and the welding head 12 longitudinally, allowing the bottom end of the welding head 12 to contact the junction box surface for welding. First brackets 11 are bolted to the side walls of the second mounting base 10. Metal tubes 13 are inserted into the ends of the first brackets 11 near the welding head 12, and plastic tubes 14 are inserted into the top ends of the metal tubes 13. The other two ends of the connecting pipe 3 are connected to the plastic tubes 14. To improve the stability of air intake, the first bracket 11 and the metal pipe 13 are symmetrically distributed. The bottom end of the metal pipe 13 is arc-shaped and the bottom end of the metal pipe 13 is threaded with a nozzle 17. The nozzle 17 is directly opposite the bottom end of the welding head 12, which improves the stability of air output. When the welding head 12 is completed, the blower 2 can generate air force that is evenly sprayed through the connecting pipe 3, the three-way pipe 4, the plastic pipe 14, the metal pipe 13, and then through the nozzle 17, thereby blowing and cleaning the surface of the weld joint, thereby accelerating the cooling and solidification of the weld joint, and thus improving the quality and efficiency of the junction box welding and shaping.

[0033] Both first brackets 11 have first slots 18 on their surfaces, through which metal tubes 13 pass in sequence, improving the ease of installation and positioning of metal tubes 13. Both second mounting bases 10 have second brackets 16 fixed on their side walls near the metal tubes 13, and both second brackets 16 have second slots 19 on their surfaces for the metal tubes 13 to be inserted, improving the overall stability of the metal tubes 13.

[0034] The end of the second support 16 is provided with a sliding groove 20. The sliding groove 20 is L-shaped and passes through the top of the second support 16. The plastic tube 14 is slidably connected in the middle of the sliding groove 20, which improves the stability of the movement of the plastic tube 14. A filter 21 is inserted into the input end of the side wall of the blower 2. The middle of the filter 21 is filled with activated carbon filter cotton, which improves the safety of the purified air.

[0035] When using this junction box welding shaping auxiliary device, first install the device in the designated position and then connect an external power source. Secure the junction box to be welded in the middle of the limiting seat 15. Start the slide rail 5 to move the sliding seat 6 horizontally, thus positioning the two welding heads 12 horizontally. Then, start the first electric push rod 7 to push the first mounting seat 8 and the welding heads 12 laterally, facilitating adjustment of the welding points of the two welding heads 12. Start the second electric push rod 9 to move the two welding heads 12 vertically, allowing the bottom of the welding heads 12 to contact the junction box surface for welding. When the high welding temperature causes the weld joint to melt, the operator starts the blower 2 to generate airflow that is evenly sprayed through the connecting pipe 3, tee pipe 4, plastic pipe 14, and metal pipe 13, then through the nozzle 17, thus cleaning the weld joint surface and accelerating its cooling and solidification, thereby improving the quality and efficiency of junction box welding shaping.

[0036] Considering that the plastic tube 14 is flexible and may become disordered when it moves with the second mounting base 10, the plastic tube 14 is inserted into the sliding groove 20 by providing the second bracket 16 and the sliding groove 20, thereby improving the overall stability of the sliding of the plastic tube 14.

[0037] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A junction box welding shaping aid, characterized by, The utility model relates to an organic frame (1) is provided with a blower (2) on the surface of the frame (1), the top end of the blower (2) is inserted with a communication pipe (3), a tee pipe (4) is inserted on the side wall of the frame (1), a slide rail (5) is fixed on the side wall of the frame (1) near the tee pipe (4), a sliding seat (6) is movably connected on the side wall of the slide rail (5), two first electric push rods (7) are fixed on the side wall of the sliding seat (6), the output end of the two first electric push rods (7) is fixed with a first mounting seat (8), a second electric push rod (9) is fixed on the side wall of the first mounting seat (8), the output end of the second electric push rod (9) is fixed with a second mounting seat (10), a welding head (12) is fixed on the bottom end of the second mounting seat (10), a first support (11) is fixed on the side wall of the second mounting seat (10), a metal pipe (13) is inserted on the end of the first support (11) near the welding head (12), and a plastic pipe (14) is inserted on the top end of the metal pipe (13).

2. A junction box welding contouring aid as defined in claim 1, wherein: One end of the tee pipe (4) penetrates the frame (1) and is connected with the other end of the communication pipe (3), and the other two ends of the communication pipe (3) are connected with the plastic pipe (14).

3. A junction box welding contouring aid as defined in claim 1, wherein: The first support (11) and the metal pipe (13) are symmetrically distributed, the bottom end of the metal pipe (13) is in arc shape, a nozzle (17) is threadedly connected on the bottom end of the metal pipe (13), and the nozzle (17) is opposite to the bottom end of the welding head (12).

4. A junction box welding contouring aid as defined in claim 1, wherein: First insertion grooves (18) are formed on the surfaces of the two first supports (11), and the metal pipes (13) penetrate the first insertion grooves (18) in sequence.

5. A junction box welding contouring aid as defined in claim 1, wherein: Second supports (16) are fixed on the side walls of the two second mounting seats (10) near the metal pipes (13), second insertion grooves (19) are formed on the surfaces of the second supports (16) for the metal pipes (13) to be inserted.

6. A junction box welding contouring aid as defined in claim 1, wherein: Ends of the second supports (16) are provided with sliding grooves (20), the sliding grooves (20) are L-shaped and penetrate the top ends of the second supports (16), and the plastic pipes (14) are slidingly connected in the middle of the sliding grooves (20).

7. A junction box welding contouring aid as defined in claim 1, wherein: An input end of a side wall of the blower (2) is inserted with a filter (21), and the filter (21) is filled with activated carbon filter cotton in the middle.

8. A junction box welding contouring aid as defined in claim 1, wherein: Limiting seats (15) are fixed on the surfaces of the frame (1) near the two welding heads (12), recesses are formed in the middle of the limiting seats (15) for the junction boxes to be clamped.

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