A photovoltaic module assembly system

Abstract

This utility model discloses a photovoltaic module assembly system, which includes a welding area and an adhesive application area arranged sequentially along the X direction. The welding area outputs materials along the X direction. The adhesive application area includes, along the X direction, a tape applicator, a small long-side strip placement machine, a short-side strip placement machine, a second-layer adhesive film laying machine, a backsheet cutting and laying machine, a sheet assembly machine, a lead wire bending and high-temperature cloth laying machine, a front EL inspection machine, and an edge sealing machine, all arranged sequentially along the X direction on the output side of the welding area. This utility model can meet the production needs of various types of battery modules, has a scientific and reasonable layout, reduces the production line floor space, and lowers production line costs.

Description

[Technical Field]

[0001] This utility model belongs to the technical field of photovoltaic module production line, and in particular relates to a photovoltaic module assembly system. [Background Technology]

[0002] The core component of solar photovoltaic (PV) power generation is the solar cell, which works by directly converting solar radiation into electrical energy based on the photovoltaic effect of semiconductors. There are many types of solar cell modules, such as crystalline silicon solar modules (monocrystalline silicon modules, polycrystalline silicon modules, high-efficiency crystalline silicon modules such as PERC / TOPCon / HJT / BC), thin-film solar modules (amorphous silicon thin-film modules, cadmium telluride thin-film modules, copper indium gallium selenide thin-film modules, etc.), and emerging technologies (perovskite solar modules, organic photovoltaics, etc.). Currently, crystalline silicon solar modules remain the mainstream technology, accounting for approximately 90%.

[0003] With the emergence of various photovoltaic (PV) modules, many PV module manufacturers no longer produce only one type of module. Instead, a single production line may simultaneously handle the automated production of multiple different types of PV modules. Therefore, the flexibility and compatibility of PV module production lines have become particularly important. Furthermore, due to the numerous assembly processes involved in PV modules, the overall length of PV module production lines is relatively long, and they occupy a large area. Therefore, the optimized layout of PV module production lines is also crucial. The layout of upstream and downstream processes, as well as the shape design of the line, directly affect module production efficiency, number of employees, logistics, and equipment costs.

[0004] The existing patent CN213124467U discloses a fully automated production line for photovoltaic modules. Although it achieves automated assembly of photovoltaic modules, the production line has the following drawbacks:

[0005] (1) The laying process only includes the back EVA loading area and the back sheet loading area, which cannot meet the assembly requirements of the currently popular TOPCon battery modules or BC battery modules, and has poor versatility.

[0006] (2) The welding process only includes three battery cell string welding machines, which has a low capacity and cannot meet the production needs of higher capacity requirements.

[0007] Therefore, it is necessary to provide a new photovoltaic module assembly system to solve the above-mentioned technical problems. [Utility Model Content]

[0008] The main purpose of this utility model is to provide a photovoltaic module assembly system that can meet the production needs of various types of battery modules. The system has a scientific and reasonable layout, reduces the floor space occupied by the production line, and lowers the production line cost.

[0009] This utility model achieves the above objectives through the following technical solution: a photovoltaic module assembly system, comprising a welding area and an adhesive application area distributed sequentially along the X direction; the welding area outputs materials along the X direction;

[0010] The adhesive application area includes sections arranged sequentially along the X direction on the output side of the welding area:

[0011] A tape applicator is used to attach and fix the battery strings to a glass panel.

[0012] The small block long-side strip placement machine places two short-side adhesive strips on one long side of a glass and a piece of adhesive at the lead wire.

[0013] Short-side strip placement machine: Places two long-side adhesive strips on the short side of a glass pane.

[0014] The two-layer adhesive film laying machine lays two layers of adhesive film on top of the battery string;

[0015] The back panel cutting and laying machine lays the back panel above the second layer of adhesive film;

[0016] The laminating machine combines two glass covers onto one glass cover to achieve lamination.

[0017] The high-temperature cloth is placed on the lead wire and bent flat.

[0018] Furthermore, the welding area includes a first conveyor line that conveys materials along the X direction, a plurality of battery cell string welding machines that are arranged along the X direction on the Y-opposite side of the first conveyor line and output battery strings along the Y direction, a plurality of sorting machines that are disposed on the output side of the battery cell string welding machines and located between the battery cell string welding machines and the first conveyor line, a second conveyor line that connects all the sorting machines in parallel along the X direction and conveys materials along the X-opposite direction, and a battery string end welding machine disposed at the tail end of the first conveyor line; the adhesive application area is arranged along the extension line of the first conveyor line.

[0019] Furthermore, the cell string welding machine and the first conveyor line are respectively located on both sides of the second conveyor line in the Y direction; one layout machine is configured on the output side of every two cell string welding machines, and each layout machine is equipped with two layout robots to perform layout simultaneously; the welding area is equipped with a total of eight cell string welding machines and four layout machines.

[0020] Furthermore, a reversing mechanism is provided on the first conveyor line at the position where it connects to the typesetting machine. The typesetting machine outputs a glass plate with battery strings arranged along the long side of the Y direction onto the first conveyor line. Then, through the reversing mechanism, it is horizontally reversed and outputs a glass plate along the long side of the X direction into the battery string end welding machine, and then inputs it into the pasting and laying area for subsequent processes.

[0021] Furthermore, a first glass feeding area is provided on one side of the welding area in the X direction, and the first glass feeding area includes, in sequence along the X-reverse direction:

[0022] The first glass feeding machine supplies one layer of glass.

[0023] A coding machine sprays information codes at designated locations on a glass pane.

[0024] A film-laying machine lays a film on a piece of glass.

[0025] Furthermore, the output end of the film laying machine is provided with a first reversing conveying mechanism, and the input end of the second conveying line is provided with a second reversing conveying mechanism;

[0026] The film-laying machine outputs a piece of glass with a film laid on it along the long side in the X-direction. After being horizontally reversed by the first reversing conveyor mechanism, it outputs a piece of glass with a film laid on it along the short side in the Y-direction. The second reversing conveyor mechanism receives a piece of glass input along the short side in the Y-direction, and after being horizontally reversed, it outputs a piece of glass along the long side in the X-direction onto the second conveyor line.

[0027] Furthermore, the small piece long side strip placement machine includes a component conveying line, a strip cutting and feeding module disposed above the component conveying line, a strip handling and placement module, a small piece cutting and feeding module, and a small piece handling and placement module.

[0028] Furthermore, the bonding and laying area also includes a lead wire bending and high-temperature cloth laying machine, a front EL inspection machine, and an edge sealing machine arranged sequentially along the X direction; the lead wire bending and high-temperature cloth laying machine places high-temperature cloth at the lead wire and bends and flattens the lead wire; the front EL inspection machine includes several layers of inspection stations, and the edge sealing machine includes several layers of edge sealing stations. Both the front EL inspection machine and the edge sealing machine adopt a multi-layer structure design. A first lifting stacking line is configured on the input side of the front EL inspection machine, and a second lifting stacking line is configured on the output side of the edge sealing machine.

[0029] Furthermore, a third lifting stacking line is provided between the small piece long side strip placement machine and the short side strip placement machine; a fourth lifting stacking line is provided between the back panel cutting and laying machine and the sheet assembly machine.

[0030] Furthermore, the conveyor line at the front EL inspection machine is a reversing conveyor line with a reversing conveying function; a sixth lifting stacking line is provided on the X-direction opposite side of the front EL inspection machine; the pasting and laying area is also equipped with an AGV shuttle trolley. When the buffer quantity of the sixth lifting stacking line reaches a set value, the defective products are taken out by the AGV shuttle trolley and transferred to the rework area for centralized rework processing. After the rework is qualified, the defective products are sent back to the sixth lifting stacking line by the AGV shuttle trolley and then returned to the front EL inspection machine by the sixth lifting stacking line.

[0031] Furthermore, a second glass feeding area is provided on the Y-direction opposite side of the laminating machine; the second glass feeding area includes a second glass feeding machine and a third reversing conveyor line, the second glass feeding machine outputs two pieces of glass along the long side of the X direction, and after being reversed by the third reversing conveyor line, outputs two pieces of glass along the short side of the Y direction; a fifth lifting stacking line is provided on the Y-direction output side of the third reversing conveyor line.

[0032] Furthermore, a second glass feeding area is provided on the Y-direction side of the laminating machine; the second glass feeding area includes a second glass feeding machine and a gap film bonding device provided on the output side of the second glass feeding machine; the gap film bonding device includes a long-side gap film feeding and bonding unit, a short-side gap film feeding and bonding unit, a first conveying mechanism, and a second conveying mechanism.

[0033] Furthermore, the second glass feeder outputs two layers of glass along the long side of the X direction to the second glass feeding station. The long side gap film feeding and pasting unit is located on the X-direction output side of the second glass feeding station. The first conveying mechanism conveys the two layers of glass from the second glass feeding station along the X direction to the long side gap film feeding and pasting unit for automatic pasting of the long side gap film. The short side gap film feeding and pasting unit is located on the Y-direction side of the long side gap film feeding and pasting unit and is close to the laminator. The second conveying mechanism moves the two layers of glass from the long side gap film feeding and pasting unit to the short side gap film feeding and pasting unit after a horizontal reversal. The laminator robot in the laminator picks up the two layers of glass with the gap film pasted on their lower surface from the short side gap film feeding and pasting unit and covers them onto a single layer of glass to complete the lamination.

[0034] Compared with existing technologies, the advantages of this photovoltaic module assembly system are: it can meet the production needs of various types of battery modules, its layout is scientific and reasonable, it reduces the floor space required for the production line, and it lowers the production line cost. Specifically:

[0035] (1) In the welding area, all the cell string welding machines are arranged along the X direction, and each cell string welding machine is set up along the Y direction to output the cell strings. A layout machine is set up on the output side of the cell string welding machine. The second conveyor line is used to connect all the layout machines and serve as a feeding conveyor line for a glass in the welding area. After the glass is conveyed to the layout machine, it is efficiently laid out by two robots and then output along the Y direction to the first conveyor line. All the glass with the laid-out cell strings is output to the right along the X direction from the first conveyor line and conveyed to the cell string end welding machine at the end of the first conveyor line for end welding operation. The whole layout is reasonable, occupies a small area, and has eight cell string welding machines in parallel, which greatly improves the production capacity.

[0036] (2) The first glass loading area is set at the beginning of the second conveyor line, and overlaps with the subsequent pasting area in the X direction. Therefore, the length of the entire production line will not be increased. A coding machine is set in the first glass loading area. The coding machine directly sprays the information code on a glass, which improves the security of the information code on the glass and ensures the reliability of subsequent reading of the information code. On the other hand, it eliminates the need for subsequent information barcode printing and information code pasting mechanisms.

[0037] (3) Small long-side strip placement machine, short-side strip placement machine, sheet assembly machine, lead wire bending and high-temperature cloth laying machine are set up in the pasting and laying area to meet the production process requirements of Topcon battery modules; at the same time, the entire production line can also meet the process requirements of conventional battery modules.

[0038] (4) A gap film bonding device is set in the second glass feeding area. While meeting the production process requirements of Topcon battery modules, it can also meet the production process requirements of BC battery modules, which improves the flexibility and versatility of the production line and can meet the production needs of various types of battery modules.

[0039] (5) All equipment in the pasting and laying area is arranged sequentially along the extension line of the first conveyor line in the welding area. A blank area is reserved in the X direction area of ​​the battery cell string welding machine and the layout machine and on the Y direction side of the pasting and laying area. This blank area is used to lay out the first glass feeding area and the second glass feeding area. It does not occupy the area of ​​the length and width expansion of the entire production line. The layout is scientific and reasonable. The logistics of the entire production line does not have too many twists and turns. Compared with the original production line at the customer's site, it saves up to 35 sets of production lines, reduces the cost of the production line, and shortens the length of one laminator in the X direction of the entire line, reducing the floor space. [Attached Image Description]

[0040] Figure 1 This is a top view schematic diagram of an embodiment of the present utility model;

[0041] Figure 2 This is a top view of the welding area in an embodiment of the present invention;

[0042] Figure 3 This is a top view of the first glass loading area in an embodiment of this utility model;

[0043] Figure 4 This is a top view of the small block long side strip placement machine in an embodiment of this utility model;

[0044] Figure 5 This is a top view of the second glass feeding area in an embodiment of the present invention;

[0045] Figure 6 This is a top view schematic diagram of another structure of the second glass feeding area in an embodiment of this utility model;

[0046] Figure 7 This is a top view of the lamination area in an embodiment of the present invention;

[0047] The numbers in the diagram represent:

[0048] 100 - Photovoltaic module assembly system;

[0049] 10-Welding area, 11-First conveyor line, 111-Reversing mechanism, 12-Battery cell string welding machine, 13-Layout machine, 14-Second conveyor line, 15-Battery string end welding machine;

[0050] 20-Paste application area, 21-Tape applicator, 22-Small piece long side strip placement machine, 221-Component conveyor line, 222-Long strip cutting and feeding module, 223-Long strip handling and placement module, 224-Small piece cutting and feeding module, 225-Small piece handling and placement module, 23-Short side strip placement machine, 24-Second-layer adhesive film laying machine, 25-Back panel cutting and laying machine, 26-Piece assembly machine, 27-Lead wire bending and high-temperature cloth laying machine, 28-Front EL inspection machine, 29-Edge sealing machine, 210-First lifting and stacking line, 211-Second lifting and stacking line, 212-Third lifting and stacking line, 213-Fourth lifting and stacking line, 214-Sixth lifting and stacking line, 215-AGV connecting trolley;

[0051] 30-Lamination zone, 31-Laminator, 32-Third conveyor line, 33-Seventh lifting and stacking line;

[0052] 40-First glass feeding area, 41-First glass feeding machine, 42-Inkjet printer, 43-First adhesive film laying machine, 44-First reversing conveyor mechanism, 45-Second reversing conveyor mechanism, 46-Buffer mechanism;

[0053] 50-Second glass loading area, 51-Second glass loading machine, 52-Third reversing conveyor line, 53-Fifth lifting and stacking line, 54-Gap film pasting equipment, 541-Long side gap film feeding and pasting unit, 542-Short side gap film feeding and pasting unit, 543-First handling mechanism, 544-Second handling mechanism, 55-Second glass loading station.

Detailed Implementation Methods

[0054] Example 1:

[0055] Please refer to Figures 1-7 This embodiment is a photovoltaic module assembly system 100, which includes a welding area 10, an adhesive laying area 20 and a lamination area 30 distributed sequentially along the X direction. The glass feeding end of the welding area 10 is provided with a first glass feeding area 40, and the second glass feeding end of the adhesive laying area 20 is provided with a second glass feeding area 50.

[0056] The welding area 10 includes a first conveyor line 11 that conveys materials along the X direction, a plurality of battery cell string welding machines 12 that are arranged along the X direction and distributed on one side of the first conveyor line 11 in the Y direction and output battery strings in the Y direction, a plurality of sorting machines 13 that are arranged on the output side of the battery cell string welding machines 12 and located between the battery cell string welding machines 12 and the first conveyor line 11, a second conveyor line 14 that connects all the sorting machines 13 in parallel along the X direction and conveys materials in the opposite direction of X, and a battery string end welding machine 15 that is arranged at the tail end of the first conveyor line 11.

[0057] The first conveyor line 11 and the second conveyor line 14 are distributed parallel to each other and convey materials along the X direction. The first conveyor line 11 conveys materials in the positive X direction, and the second conveyor line 14 conveys materials in the opposite X direction. The pasting and laying area 20 is connected to the end of the first conveyor line 11, and the first glass feeding area 40 is connected to the beginning of the second conveyor line 14. The first conveyor line 11 conveys a glass plate with battery strings to the subsequent battery string end welding machine 15; the second conveyor line 14 conveys a glass plate to each of the stacking machines 13.

[0058] Several cell stringing machines 12 are arranged along the X-direction, and each cell stringing machine 12 extends along the Y-direction. The cell stringing machines 12 and the first conveyor line 11 are located on opposite sides of the second conveyor line 14 in the Y direction. To improve the production cycle time and production line capacity, in this embodiment, one layout machine 13 is configured on the output side of every two cell stringing machines 12. Each layout machine 13 is equipped with two layout robots that perform layout simultaneously to improve the production cycle time. In this embodiment, a total of eight cell stringing machines 12 and four layout machines 13 are set up, and the production cycle time can reach 12 seconds.

[0059] Both the cell string welding machine 12 and the layout machine 13 can adopt the structures in the prior art. For example, the layout machine 13 can adopt the dual-robot high-efficiency layout machine disclosed in patent 202420500477.5, or a photovoltaic module cell string high-speed layout equipment disclosed in patent 202421168911.0, or a multi-to-multi string welding layout continuous production line disclosed in patent 202311009347.8, etc.

[0060] A reversing mechanism 111 is provided at the docking position of the first conveyor line 11 with the layout machine 13. The layout machine 13 outputs a glass with battery strings on the first conveyor line 11 along the long side of the Y direction. Then, the direction of the glass is adjusted by the reversing mechanism 111, and then a glass is output along the long side of the X direction to the battery string end welding machine 15, and then input into the pasting and laying area 20 for subsequent processes.

[0061] The first glass feeding area 40 includes a first glass feeding machine 41, a coding machine 42, and a first film laying machine 43 arranged sequentially in the opposite direction of X.

[0062] The first glass feeder 41 is used to realize the automatic feeding of one glass layer. It can adopt the structure in the prior art, such as the photovoltaic module glass feeding device disclosed in patent 202420171430.9.

[0063] The inkjet printer 42 is used to spray information codes at designated locations on a glass plate during material feeding.

[0064] A single-layer adhesive film laying machine 43 is used to lay a layer of EVA adhesive film on a single layer of glass.

[0065] In this embodiment, a coding machine 42 is installed between the first glass loading machine 41 and the first adhesive film laying machine 43. An information code is sprayed on the glass when it enters the production line. Compared with the original method of adding a barcode pasting mechanism or equipment on the lower surface of the glass plate at the designated station in the adhesive laying area 20, this method eliminates the need for subsequent addition of such a mechanism or equipment. Furthermore, when using the adhesive method to paste the information code onto the glass plate, there is a risk that the information code may fall off as the glass plate moves through various stations along the production line, making it impossible to obtain the information code to generate an associated barcode. However, the method of obtaining the information code by spraying does not have the above-mentioned risk problem.

[0066] To achieve high-efficiency cycle time, in this embodiment, the first glass feeder 41 adopts a dual-station feeding method, with the two feeding stations arranged along the Y direction. Therefore, the overall length of the first glass feeder 41 along the Y direction is relatively large, making it impossible to position the output side of the first glass feeder 41 on the extension line of the second conveyor line 14. Consequently, the output side of the first glass feeder 41 can only be offset in the opposite Y direction. Therefore, to achieve the docking of the first glass feeding area 40 and the welding area 10, this embodiment provides a first reversing conveyor mechanism 44 at the output end of the first film laying machine 43 and a second reversing conveyor mechanism 45 at the input end of the second conveyor line 14. The docking between the first glass feeding area 40 and the welding area 10 is achieved through the second reversing conveyor mechanism 45.

[0067] Specifically, the film-laying machine 43 outputs a piece of glass with a film laid on it along the long side in the X direction, and then outputs a piece of glass with a film laid on it along the short side in the Y direction through the first reversing conveyor mechanism 44, thereby realizing the feeding and output of a piece of glass in the first glass feeding area 40.

[0068] The first glass feeding area 40 outputs a piece of glass with a film laid on it along the short side of the Y direction. The second reversing conveyor mechanism 45 receives the glass input along the short side of the Y direction and then outputs a piece of glass along the long side of the opposite X direction onto the second conveyor line 14.

[0069] To adjust the cycle time between the first glass feeding area 40 and the welding area 10, ensuring smooth production at each station and avoiding blockages and downtime, the first reversing conveyor mechanism 44 in this embodiment is a reversing lifting and buffering mechanism with lifting and buffering functions. In other embodiments, the first reversing conveyor mechanism 44 can also be set on the output side of the film laying machine 43, and then a buffering mechanism 46 can be connected to the output side of the first reversing conveyor mechanism 44, with the output side of the buffering mechanism 46 then connected to the second reversing conveyor mechanism 45.

[0070] To accommodate the assembly needs of various types of photovoltaic modules, the bonding and laying area 20 in this embodiment has been optimized. Specifically, the bonding and laying area 20 includes a tape applicator 21, a small long-side strip placement machine 22, a short-side strip placement machine 23, a second-layer adhesive film laying machine 24, a backsheet cutting and laying machine 25, a laminating machine 26, a lead wire bending and high-temperature cloth laying machine 27, a front EL inspection machine 28, and an edge sealing machine 29 arranged sequentially along the extension line of the first conveyor line 11. The second glass feeding area 50 is connected to the laminating machine 26.

[0071] A glass panel carrying EVA film and several battery strings is fed into the pasting area 20 along the long side of the X direction. A tape applicator 21 applies tape to designated locations, primarily to secure adjacent battery strings together. A small long-side strip placement machine 22 places two long-side EVA strips at designated locations on the long side and places small EVA pieces at three lead wire locations. A short-side strip placement machine 23 places two short-side EVA strips at designated locations on the short side. The second layer of film is then laid by a second film application machine 24. The process involves cutting and laying two layers of EVA film; cutting and laying the backing plate TPT using the backing plate cutting and laying machine 25; assembling the two layers of glass from the second glass feeding area 50 using the laminating machine 26; applying high-temperature cloth at three lead wire locations using the lead wire bending and high-temperature cloth laying machine 27, then bending and flattening the lead wires for subsequent lamination; performing EL testing using the front EL testing machine 28; sealing the edges around the glass using the edge sealing machine 29; and finally, entering the lamination area 30.

[0072] The tape applicator 21 can adopt a structure in the prior art, such as the automatic tape applicator for battery string components disclosed in patent CN214692516U, or the high-efficiency tape applicator for fixing photovoltaic module battery strings disclosed in CN221420191U.

[0073] The small piece long-side strip placement machine 22 includes a module conveyor line 221, a strip cutting and feeding module 222, a strip handling and placement module 223, a small piece cutting and feeding module 224, and a small piece handling and placement module 225, all positioned above the module conveyor line 221. The strip cutting and feeding module 222 and the strip handling and placement module 223 can refer to the photovoltaic module processing film cutting and placement machine disclosed in CN221026771U. The small piece cutting and feeding module 224 and the small piece handling and placement module 225 can adopt existing structures, such as the structure related to the punching, cutting, and placement of insulating small pieces in a small piece punching, cutting, placement, and multi-functional labeling integrated device disclosed in patent CN222396010U, or an integrated device for cutting and laying insulating sheets disclosed in CN219726520U, or a fully automatic insulating sheet placement machine for photovoltaic modules disclosed in CN215911436U, etc.

[0074] The short-side long strip placement machine 23 and the long-side long strip placement module 221 have basically the same structure. The difference is that the short-side long strip placement machine 23 realizes the cutting and placement of EVA long strips on the short side.

[0075] The lead wire bending and high-temperature laying machine 27 can adopt the structure of existing technology, such as a photovoltaic module lead wire insulation block placement and hot-pressing device disclosed in patent CN222396004U, an integrated device for cutting and laying insulation sheets disclosed in CN219726520U, or a fully automatic insulation sheet placement machine for photovoltaic modules disclosed in CN215911436U.

[0076] The placement of EVA blocks is similar to that of high-temperature cloth. Both require the lead wires to be shaped and straightened to facilitate the placement of EVA blocks or high-temperature cloth. The difference is that after the high-temperature cloth is placed in place, the lead wires need to be bent and flattened, while the EVA blocks do not need to be bent and flattened after placement.

[0077] To adjust the production cycle time, both the front EL inspection machine 28 and the edge banding machine 29 can adopt a multi-layer structure design. Specifically, the front EL inspection machine 28 has several layers of inspection stations distributed vertically, and the edge banding machine 29 has several layers of edge banding stations distributed vertically and corresponding to the height of the inspection stations. A first lifting stacking line 210 is configured on the input side of the front EL inspection machine 28, and a second lifting stacking line 211 is configured on the output side of the edge banding machine 29. This multi-layer structure design allows for simultaneous EL inspection and edge banding operations on multiple photovoltaic modules, thereby improving production efficiency and meeting the 12-second cycle time requirement.

[0078] To ensure the smooth operation of each station in the pasting and laying area 20 and to avoid material blockage and machine downtime, a third lifting and stacking line 212 is provided between the small piece long side strip placement machine 22 and the short side strip placement machine 23; and a fourth lifting and stacking line 213 is provided between the back panel cutting and laying machine 25 and the sheet assembly machine 26.

[0079] If defective products are found at the front EL inspection machine 28, they need to be transferred to the manual rework area for repair. To achieve this function, in this embodiment, the conveyor line at the front EL inspection machine 28 is set as a reversing conveyor line with a reversing conveying function, and a sixth lifting stacking line 214 is set on the X-direction opposite side of the front EL inspection machine 28 to buffer defective components. This embodiment also includes an AGV shuttle trolley 215. When the number of defective products buffered by the sixth lifting stacking line 214 reaches a set value, the AGV shuttle trolley 215 removes the defective products and transfers them to the rework area for centralized rework processing.

[0080] In this embodiment, the second glass feeding area 50 includes a second glass feeding machine 51 and a third reversing conveyor line 52. The second glass feeding machine 51 outputs two sheets of glass along the long side in the X direction, and after being reversed by the third reversing conveyor line 52, it outputs two sheets of glass along the short side in the Y direction. A fifth lifting stacking line 53 is provided on the Y-direction output side of the third reversing conveyor line 52, through which two sheets of glass are provided to the laminator 26.

[0081] In another embodiment, to meet the production requirements of BC battery modules, the second glass feeding area 50 includes a second glass feeding machine 51 and a gap film bonding device 54 disposed on the output side of the second glass feeding machine 51. The gap film bonding device 54 includes a long-side gap film feeding and bonding unit 541, a short-side gap film feeding and bonding unit 542, a first conveying mechanism 543, and a second conveying mechanism 544. The gap film bonding device 54 can adopt a structure in the prior art, such as the fully automatic bonding and glass assembly equipment and method for solar cell gap reflective film disclosed in patent CN119029093B. To save space, the layout of the gap film bonding device 54 is as follows:

[0082] The second glass feeder 51 outputs two layers of glass along the long side in the X direction to the second glass feeding station 55. The long side gap film feeding and pasting unit 541 is located on the X-direction output side of the second glass feeding station 55. The first conveying mechanism 543 conveys the two layers of glass from the second glass feeding station 55 along the X direction to the long side gap film feeding and pasting unit 541 for automatic pasting of the long side gap film. The short side gap film feeding and pasting unit 542 is located on the Y-direction side of the long side gap film feeding and pasting unit 541 and is close to the laminator 26. The second conveying mechanism 544 moves the two layers of glass from the long side gap film feeding and pasting unit 541 to the short side gap film feeding and pasting unit 542 after a 90-degree horizontal reversal. The laminator robot in the laminator 26 picks up the two layers of glass with the gap film pasted on the lower surface from the short side gap film feeding and pasting unit 542 and puts them on the first layer of glass to complete the lamination.

[0083] In this embodiment, the first glass feeding area 40 and the second glass feeding area 50 are located on the same side of the bonding and laying area 20 in the Y direction on the first conveyor line 11 and its extension line, and on the opposite side in the Y direction. The first glass feeding area 40 and the second glass feeding area 50 are automatically fed by AGV trolleys for glass stacking materials. The feeding sides of the first glass feeding area 40 and the second glass feeding area 50 are arranged opposite each other, forming a centralized feeding area for glass sheets, which is conducive to the neat and orderly layout of the production line on site.

[0084] The lamination zone 30 includes several laminators 31 arranged along the Y direction and a third conveyor line 32 connecting the laminators 31 in parallel. A second lifting stack line 211 on the output side of the edge banding machine 29 has a 90-degree horizontal reversal function. The first laminator 31 is connected to the output side of the second lifting stack line 211 in the X direction. A seventh lifting stack line 33 is provided on the third conveyor line 32 corresponding to the other laminators 31, and the seventh lifting stack line 33 also has a 90-degree horizontal reversal function. The edge banding machine 29 outputs photovoltaic modules along its long side in the X direction. After passing through the second lifting stack line 211, the photovoltaic modules are divided into two paths. One path continues along the X direction into the subsequent laminators 31, while the other path, after a 90-degree horizontal reversal, outputs the photovoltaic modules along the short side in the opposite Y direction to the subsequent seventh lifting stack line 33. Then, after a 90-degree horizontal reversal by the seventh lifting stack line 33, the modules are output along the long side in the X direction to the corresponding laminator 31.

[0085] This embodiment also provides a production process based on the above-described photovoltaic module assembly system, which includes the following steps:

[0086] S1. The first glass feeding area 40 realizes the feeding, coding and film laying of a glass: the first glass feeding machine 41 feeds a glass to the production line, the coding machine 42 sprays information code at the designated position of the glass, and the film laying machine 43 lays EVA film on the glass.

[0087] S2. A glass is output from the first glass feeding area 40 along the short side of the Y direction. After being horizontally reversed by 90 degrees by the second reversing conveyor mechanism 45, it is conveyed along the long side of the opposite X direction to the second conveyor line 14 and enters the welding area 10.

[0088] S3. In the welding area 10, the battery cell string welding machine 12 outputs battery strings along the Y direction. A glass plate is transported to the layout machine 13 via the second conveyor line 14. The layout machine 13 arranges the battery strings on the glass plate according to the set method. The glass plate after layout is output to the first conveyor line 11 along the long side of the Y direction, and then transported to the battery string end welding machine 15 along the X direction to weld the busbar, connect all the battery strings together, and continue to be transported to the pasting and laying area 20 along the long side of the X direction.

[0089] S4. In the pasting and laying area 20, according to the process requirements of different types of photovoltaic modules, complete multiple or all of the following processes in sequence: tape pasting, long side strip placement, small piece placement, short side strip placement, second layer of adhesive film laying, back sheet laying, lamination, high temperature cloth placement, lead wire bending, EL testing, and edge sealing.

[0090] S5. The photovoltaic modules output from the bonding and laying area 20 are then diverted into multiple laminators for lamination.

[0091] In step S4, if a lamination operation is included, the two layers of glass are loaded at the lamination operation station via the second glass loading area 50. If a gap reflective film needs to be pasted on the lower surface of the two layers of glass, the long-side gap film and short-side gap film are automatically pasted via the gap film pasting device 54.

[0092] In this embodiment, "X direction" refers to the direction indicated by the X arrow in the accompanying drawings; "X opposite direction" refers to the opposite direction of the X arrow in the accompanying drawings; "Y direction" refers to the direction indicated by the Y arrow in the accompanying drawings; "Y opposite direction" refers to the opposite direction of the Y arrow in the accompanying drawings. "X direction" refers to the direction parallel to the X arrow in the accompanying drawings, without distinction between positive and negative; "Y direction" refers to the direction parallel to the Y arrow in the accompanying drawings, without distinction between positive and negative. The angle between the "X direction" and "Y direction" can be flexibly designed according to the actual site conditions, for example, 20 degrees to 150 degrees, preferably 90 degrees.

[0093] For those skilled in the art, various modifications and improvements can be made without departing from the inventive concept of this utility model, and these modifications and improvements all fall within the protection scope of this utility model.

Claims

1. A photovoltaic module assembly system characterized by: It includes a welding area and an adhesive application area distributed sequentially along the X direction; the welding area outputs material along the X direction; The adhesive application area includes sections arranged sequentially along the X direction on the output side of the welding area: A tape applicator is used to attach and fix the battery strings to a glass panel. The small block long-side strip placement machine places two short-side adhesive strips on one long side of a glass and a piece of adhesive at the lead wire. Short-side strip placement machine: Places two long-side adhesive strips on the short side of a glass pane. The two-layer adhesive film laying machine lays two layers of adhesive film on top of the battery string; The back panel cutting and laying machine lays the back panel above the second layer of adhesive film; The laminating machine joins two glass covers onto one glass cover to achieve lamination.

2. The photovoltaic module assembly system of claim 1, wherein: The welding area includes a first conveyor line that conveys materials along the X direction, a plurality of battery cell string welding machines that are arranged along the X direction on the opposite side of the first conveyor line in the Y direction and output battery strings along the Y direction, a plurality of layout machines that are arranged on the output side of the battery cell string welding machines and located between the battery cell string welding machines and the first conveyor line, a second conveyor line that connects all the layout machines in parallel along the X direction and conveys materials along the opposite direction of the X direction, and a battery string end welding machine arranged at the tail end of the first conveyor line; the bonding and laying area is arranged along the extension line of the first conveyor line.

3. The photovoltaic module assembly system of claim 2, wherein: The cell string welding machine and the first conveyor line are respectively located on both sides of the second conveyor line in the Y direction; one layout machine is configured on the output side of every two cell string welding machines, and two layout robots are configured in each layout machine to perform layout at the same time; a total of eight cell string welding machines and four layout machines are set up in the welding area.

4. The photovoltaic module assembly system of claim 2, wherein: A reversing mechanism is provided at the docking position of the typesetting machine on the first conveyor line. The typesetting machine outputs a glass plate with battery strings arranged along the long side of the Y direction onto the first conveyor line. Then, through the reversing mechanism, it is horizontally reversed and outputs a glass plate along the long side of the X direction into the battery string end welding machine, and then inputs it into the pasting and laying area for subsequent processes.

5. The photovoltaic module assembly system of claim 2, wherein: A first glass feeding area is provided on one side of the welding area in the X direction, and the first glass feeding area includes, in sequence along the opposite X direction: The first glass feeding machine supplies one layer of glass. A coding machine sprays information codes at designated locations on a glass pane. A film-laying machine lays a film on a piece of glass.

6. The photovoltaic module assembly system of claim 5, wherein: The output end of the film laying machine is provided with a first reversing conveyor mechanism, and the input end of the second conveyor line is provided with a second reversing conveyor mechanism. The film-laying machine outputs a piece of glass with a film laid on it along the long side in the X-direction. After being horizontally reversed by the first reversing conveyor mechanism, it outputs a piece of glass with a film laid on it along the short side in the Y-direction. The second reversing conveyor mechanism receives a piece of glass input along the short side in the Y-direction, and after being horizontally reversed, it outputs a piece of glass along the long side in the X-direction onto the second conveyor line.

7. The photovoltaic module assembly system of claim 1, wherein: The small piece long side strip placement machine includes a component conveying line, a strip cutting and feeding module, a strip handling and placement module, a small piece cutting and feeding module, and a small piece handling and placement module, all located above the component conveying line.

8. The photovoltaic module assembly system of claim 1, wherein: The bonding and laying area also includes a lead wire bending and high-temperature cloth laying machine, a front EL inspection machine, and an edge sealing machine arranged sequentially along the X direction; the lead wire bending and high-temperature cloth laying machine places high-temperature cloth at the lead wire and bends and flattens the lead wire; the front EL inspection machine includes several layers of inspection stations, the edge sealing machine includes several layers of edge sealing stations, a first lifting stacking line is configured on the input side of the front EL inspection machine, and a second lifting stacking line is configured on the output side of the edge sealing machine.

9. The photovoltaic module assembly system of claim 1, wherein: A third lifting and stacking line is provided between the small piece long side strip placement machine and the short side strip placement machine; a fourth lifting and stacking line is provided between the back panel cutting and laying machine and the sheet assembly machine.

10. The photovoltaic module assembly system of claim 8, wherein: The conveyor line at the front EL inspection machine is a reversing conveyor line with a reversing conveying function; a sixth lifting stack line is set on the X-direction opposite side of the front EL inspection machine; the pasting and laying area is also equipped with an AGV shuttle trolley. When the buffer quantity of the sixth lifting stack line reaches a set value, the defective products are taken out by the AGV shuttle trolley and transferred to the rework area for centralized rework processing. After the rework is qualified, the defective products are sent back to the sixth lifting stack line by the AGV shuttle trolley and then returned to the front EL inspection machine by the sixth lifting stack line.

11. The photovoltaic module assembly system of claim 1, wherein: The glass laminator has a second glass feeding area on the Y-direction side; the second glass feeding area includes a second glass feeder and a third reversing conveyor line. The second glass feeder outputs two glass sheets along the long side of the X direction, and after being reversed by the third reversing conveyor line, it outputs two glass sheets along the short side of the Y direction; a fifth lifting and stacking line is provided on the Y-direction output side of the third reversing conveyor line.

12. The photovoltaic module assembly system of claim 1, wherein: A second glass feeding area is provided on the Y-direction side of the laminating machine; the second glass feeding area includes a second glass feeding machine and a gap film bonding device provided on the output side of the second glass feeding machine; the gap film bonding device includes a long-side gap film feeding and bonding unit, a short-side gap film feeding and bonding unit, a first conveying mechanism, and a second conveying mechanism.

13. The photovoltaic module assembly system of claim 12, wherein: The second glass feeder outputs two sheets of glass along the long side of the X direction to the second glass feeding station. The long side gap film feeding and pasting unit is located on the X-direction output side of the second glass feeding station. The first conveying mechanism conveys the two sheets of glass from the second glass feeding station along the X direction to the long side gap film feeding and pasting unit for automatic pasting of the long side gap film. The short side gap film feeding and pasting unit is located on the Y-direction side of the long side gap film feeding and pasting unit and is close to the laminator. The second conveying mechanism moves the two sheets of glass from the long side gap film feeding and pasting unit to the short side gap film feeding and pasting unit after a horizontal reversal. The laminator robot in the laminator picks up the two sheets of glass with the gap film pasted on their lower surface from the short side gap film feeding and pasting unit and covers them onto a single sheet of glass to complete the lamination.

Images