Stacked battery string repair system

Abstract

The utility model relates to a kind of laminated battery string repair-in-system, comprising: detecting laminated battery string, determine the defect detection equipment of defective cell from the multiple cell pieces included in the laminated battery string;The welding band ablation equipment of the welding band between the defective cell and adjacent cell piece is ablated;In the case where the welding band is ablated, the transfer equipment of the defective cell is transferred.Such laminated battery string repair-in-system can avoid the problem that cell piece is easily heat damaged during repair-in.

Description

Technical Field

[0001] This utility model relates to the field of photovoltaic module manufacturing technology, and in particular to a system for repairing stacked cell strings. Background Technology

[0002] With the booming development of the new energy industry, stacked batteries have been widely used in electric vehicles, energy storage systems, and other fields due to their advantages such as high energy density and good heat dissipation performance. However, during the manufacturing process of stacked battery strings, a certain proportion of defective battery cells inevitably appear due to various factors such as fluctuations in raw material quality and difficulties in controlling the production process. If these defective battery cells are not dealt with in a timely manner, they will seriously affect the performance and reliability of the entire stacked battery string, and may even cause the battery string to become unusable, resulting in huge losses.

[0003] When traditional stacked modules are repaired, the battery encapsulation material is peeled off by heating the entire module. Since the thermal expansion coefficients of different parts of the battery are different, it is difficult to ensure that the battery cells are heated evenly by heating the entire module. The temperature gradient will generate thermal stress inside the battery cells, which will cause warping. Moreover, the battery cells are more prone to thermal damage at high temperatures. Utility Model Content

[0004] Therefore, it is necessary to provide a stacked battery string repair system to address the problem of thermal damage to battery cells that can easily occur when the battery packaging material is peeled off by heating.

[0005] A rework system for stacked battery strings, the system comprising:

[0006] A defect detection device for detecting defective cells from multiple cells in a stacked battery string;

[0007] A solder strip ablation device for ablating the solder strip between the defective battery cell and an adjacent battery cell;

[0008] In the event that the solder strip melts, a transfer device is used to transfer the defective battery cell.

[0009] In one embodiment, the solder strip ablation device is connected to the defect detection device and the transfer device; or

[0010] The system also includes control equipment;

[0011] The control device is connected to the defect detection device, the weld strip ablation device, and the transfer device.

[0012] In one embodiment, the system further includes:

[0013] A battery string preheating device for preheating the stacked battery string before the solder strip is melted.

[0014] In one embodiment, the system further includes:

[0015] A miniature pressure head array that melts the conductive adhesive between the solder ribbon and the battery cell after the battery string is preheated and before the solder ribbon is melted.

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

[0017] A temperature detection device for detecting the preheating temperature of the stacked battery string.

[0018] In one embodiment, the solder strip ablation device includes:

[0019] Laser source that emits laser light;

[0020] A laser adjustment device that adjusts the transmission direction of the laser to focus the laser onto the welding strip.

[0021] In one embodiment, the transfer device includes a transfer arm and a suction cup fixed to the end of the transfer arm.

[0022] In one embodiment, the suction cup is an adjustable suction cup, and the transfer arm is provided with a suction adjustment device, which is electrically connected to the suction cup.

[0023] In one embodiment, the suction cup surface is provided with a flexible buffer layer.

[0024] In one embodiment, the system further includes:

[0025] A cell surface treatment device is installed on the movement path of the stacked cell string after the defective cell is transferred.

[0026] In the aforementioned stacked solar cell rework system, the defect detection equipment can inspect the stacked solar cells, identify defective cells from multiple cells, accurately pinpoint the rework target, and avoid blindly heating normal cells. The solder ribbon melting equipment can melt the solder ribbon between the defective cell and adjacent cells, achieving localized operation, concentrating energy in the solder ribbon area, reducing heat diffusion to surrounding silicon wafers, reducing the degree and duration of heating on the silicon wafers, effectively avoiding thermal damage caused by overall heating, and ensuring rework quality. The transfer equipment can transfer the defective cell after the solder ribbon has been melted. Due to the precise operation in the early stage, the cell temperature is stabilized, and secondary damage caused by temperature changes, collisions, and other factors can be avoided during transfer. Therefore, in the process of stacked solar cell rework, the various devices in the system work together to solve the problem of easy thermal damage to cells in traditional rework processes. Attached Figure Description

[0027] Figure 1 This is a structural block diagram of a stacked battery string repair system in one embodiment;

[0028] Figure 2 This is a structural block diagram of a stacked battery string repair system in another embodiment;

[0029] Figure 3 This is a schematic diagram of the transfer equipment in one embodiment;

[0030] Figure 4 This is a structural block diagram of a stacked battery string repair system in another embodiment;

[0031] Figure 5 This is a structural block diagram of a stacked battery string repair system in another embodiment;

[0032] Figure 6 Here is a structural block diagram of a stacked battery string repair system in one embodiment;

[0033] Figure 7 This is a structural block diagram of the solder strip melting device in one embodiment;

[0034] Figure 8 This is a structural block diagram of a transfer device in one embodiment.

[0035] Explanation of reference numerals in the attached figures: 1-Defect detection equipment; 2-Strip ablation equipment; 21-Laser source; 22-Laser adjustment device; 3-Transfer equipment; 31-Transfer arm; 32-Suction cup; 4-Battery string preheating equipment; 5-Miniature pressure head array; 6-Temperature detection equipment. Detailed Implementation

[0036] To make the above-mentioned objects, features, and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a full understanding of this utility model. However, this utility model can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this utility model. Therefore, this utility model is not limited to the specific embodiments disclosed below.

[0037] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0038] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this utility model, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0039] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; 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 communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0040] In this utility model, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0041] It should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0042] As described in the background section, with the booming development of the new energy industry, stacked batteries have been widely used in electric vehicles, energy storage systems, and other fields due to their advantages such as high energy density and good heat dissipation performance. However, during the manufacturing process of stacked battery strings, a certain proportion of defective battery cells inevitably appear due to various factors such as fluctuations in raw material quality and difficulties in controlling the production process. If these defective battery cells are not dealt with in a timely manner, they will seriously affect the performance and reliability of the entire stacked battery string, and may even cause the battery string to become unusable, resulting in huge losses.

[0043] When traditional stacked modules are repaired, the battery encapsulation material is peeled off by heating the entire module. Since the thermal expansion coefficients of different parts of the battery are different, it is difficult to ensure that the battery cells are heated evenly by heating the entire module. The temperature gradient will generate thermal stress inside the battery cells, which will cause warping. Moreover, the battery cells are more prone to thermal damage at high temperatures.

[0044] Based on this, such as Figure 1 As shown, a rework system for stacked battery strings is proposed. The system includes: a defect detection device 1 for detecting stacked battery strings and identifying defective battery cells from the multiple battery cells contained in the stacked battery strings; a solder strip ablation device 2 for ablation of the solder strips between the defective battery cell and adjacent battery cells; and a transfer device 3 for transferring the defective battery cell in the case of solder strip ablation.

[0045] Stacked cell strings are battery modules formed by stacking and connecting multiple cells together using a specific process. This structure can improve the power density and energy density of the battery module, but it is relatively difficult to repair. Defective cells are those in the stacked cell string that have abnormal performance, appearance damage, or other problems that affect the overall performance of the string. Solder ribbons are metal strips used to connect the cells and enable current conduction; they are usually made of materials with good conductivity, such as copper.

[0046] Defect detection equipment 1 utilizes optical, electrical, and image processing technologies to detect and analyze stacked solar cell strings to determine the presence and precise location of defective cells. For example, defect detection equipment 1 can be an optical sensor (such as a camera or laser scanner) or an electrical detection device. Solder ribbon ablation equipment 2 uses a specific energy source (such as a laser or hot air) to heat the solder ribbon between the defective cell and adjacent cells, melting or vaporizing it to separate the solder ribbon from the cell. Transfer equipment 3 is used to remove the defective cell, separated from adjacent cells after solder ribbon ablation, from the stacked solar cell string and transfer it to a designated location (such as a recycling area or rework area). For example, the laser ablation wavelength could be 1100nm, the power 10W-20W, and the scanning speed 10mm / s-50mm / s.

[0047] Specifically, defect detection equipment 1 utilizes optical, electrical, or image processing technologies to conduct comprehensive and detailed inspections of stacked battery strings. It acquires images of the battery strings using a high-resolution camera, analyzes the appearance of the battery cells using advanced image recognition algorithms, and simultaneously performs electrical tests to detect battery cell performance parameters such as voltage and current. This accurately identifies defective battery cells with appearance defects such as cracks or abnormal colors, or those that do not meet performance standards, and precisely marks their location information, providing accurate guidance for subsequent operations. This step greatly improves the accuracy of rework, avoiding damage to normal battery cells caused by traditional blind rework, ensuring that only truly defective battery cells are processed, thus guaranteeing rework quality from the source. At the same time, precise positioning reduces the additional time and resource waste caused by inaccurate positioning in subsequent operations, improving overall rework efficiency.

[0048] like Figure 2 As shown, after receiving precise location information transmitted by the defect detection device 1, the solder strip ablation device 2 quickly moves its operating components (such as a laser emitter or hot air nozzle) to the location of the solder strip a between the defective cell and the adjacent cell. Taking laser ablation as an example, the laser source emits a high-energy laser beam, which is focused by the optical system and precisely irradiates the solder strip, causing it to rapidly heat up to its melting or vaporization point, thus separating the solder strip from the cell. During the ablation process, the device monitors the state of the solder strip in real time to ensure that the ablation effect meets the standards and does not damage the surrounding cells. This precise solder strip ablation method further improves the rework accuracy, ensures the overall performance of the battery string, and at the same time, automated operation reduces manual intervention, improves rework efficiency, and reduces the quality risk caused by human error. Figure 2 and Figure 3 As shown, when the solder strip melts, the transfer device 3 can transfer the defective cell b.

[0049] For example, the transfer device 3 can consist of a robotic arm with multiple degrees of freedom and a gripping device such as an end-effector suction cup. Based on the position information provided by the defect detection device 1, the robotic arm accurately moves the suction cup to the location of the defective battery cell, grasps the cell using negative pressure adsorption, and transfers it to a designated location, such as a recycling container. This process achieves rapid and accurate transfer of defective battery cells, avoiding collisions and damage that may occur during manual handling, and improving the safety and efficiency of the transfer. At the same time, automated transfer reduces labor costs, accelerates the rework process, and makes the entire rework system more efficient and stable.

[0050] In the aforementioned stacked solar cell rework system, defect detection device 1 can detect the stacked solar cell string, identify defective cells from multiple cells, accurately pinpoint the rework target, and avoid blindly heating normal cells. Solder ribbon melting device 2 can melt the solder ribbon between the defective cell and adjacent cells, achieving localized operation, concentrating energy in the solder ribbon area, reducing heat diffusion to surrounding silicon wafers, and minimizing the degree and duration of heating on the silicon wafers. This effectively avoids thermal damage caused by overall heating and ensures rework quality. Transfer device 3 can transfer the defective cell after solder ribbon melting. Due to the precise operation in the early stages, the cell temperature is stabilized, and secondary damage caused by temperature changes, collisions, etc., can be avoided during transfer. Therefore, in the process of stacked solar cell rework, the various devices in the system work together to solve the problem of easy thermal damage to cells in traditional rework processes.

[0051] In one embodiment, the solder strip ablation device 2 is connected to the defect detection device 1 and the transfer device 3; or the system further includes a control device; the control device is connected to the defect detection device 1, the solder strip ablation device 2 and the transfer device 3.

[0052] Among them, the control equipment is the core control unit of the system. Through preset programs and algorithms, it performs unified scheduling and control of defect detection equipment 1, weld strip melting equipment 2 and transfer equipment 3, realizes the collaborative work between the equipment, and ensures the automation and intelligence of the entire rework process.

[0053] Specifically, when the solder strip ablation device 2 is connected to the defect detection device 1 and the transfer device 3, after the defect detection device 1 completes the inspection of the stacked battery string, it directly transmits the location information of the detected defective battery cell to the solder strip ablation device 2. Based on the received location information, the solder strip ablation device 2 adjusts its operating components (such as a laser emitter or hot air nozzle) to the designated position to ablate the solder strip between the defective battery cell and adjacent cells. After the solder strip ablation is completed, the solder strip ablation device 2 transmits the completion signal to the transfer device 3. The transfer device 3, according to a preset path and operating method, removes the defective battery cell from the battery string and transfers it to the designated location. The entire process achieves collaborative work through direct signal transmission between the devices, reducing manual intervention and improving rework efficiency.

[0054] When the control equipment is connected to defect detection equipment 1, solder strip ablation equipment 2, and transfer equipment 3, defect detection equipment 1 transmits the detected defective cell information (including location, defect type, etc.) to the control equipment. Based on this information, the control equipment formulates a detailed rework plan and sends solder strip ablation operation instructions to solder strip ablation equipment 2, including parameters such as ablation location, ablation energy, and ablation time. Solder strip ablation equipment 2 performs the solder strip ablation operation according to the instructions and provides real-time feedback on the operation's status information (such as ablation progress and equipment operating status) to the control equipment. After solder strip ablation is completed, the control equipment sends a transfer instruction to transfer equipment 3, controlling it to accurately pick up and transfer the defective cell. Simultaneously, the control equipment can monitor and record the entire rework process for subsequent quality traceability and data analysis.

[0055] In this embodiment, whether the solder strip ablation device 2 is directly connected to the defect detection device 1 and the transfer device 3, or is uniformly controlled through a control device, automated collaborative work between the devices is achieved. This reduces the time and error of manual operation, avoids waiting and downtime caused by manual intervention, and greatly improves the rework efficiency of stacked battery strings, meeting the needs of large-scale production.

[0056] In one embodiment, such as Figure 4 As shown, the system also includes a battery string preheating device 4 for preheating the stacked battery strings before the solder strips are melted. The battery string preheating device 4 is connected to the defect detection device 1 and the solder strip melting device 2.

[0057] The battery string preheating equipment 4 is a device that heats the stacked battery strings before the solder strips are melted, thereby increasing the temperature of the battery strings and creating more favorable conditions for the subsequent solder strip melting operation. For example, the battery string preheating equipment 4 can be a base plate heating device, a hot air circulation preheating device, or an infrared radiation preheating device.

[0058] Specifically, during the rework process of stacked battery strings, when a defective battery cell is identified and solder strip ablation is prepared, the battery string preheating equipment 4 is activated first. This preheating equipment typically uses heating plates, hot air circulation devices, or infrared heating to heat the stacked battery strings. Once the battery strings are preheated to the designated temperature, the solder strip ablation equipment 2 begins operation. Because the battery strings have been preheated, the temperature of the solder strip itself has also increased, and its physical properties (such as melting point and hardness) will change to some extent. Based on the defective battery cell location information provided by the defect detection equipment 1, the solder strip ablation equipment 2 moves its operating components (such as a laser emitter or hot air nozzle) to the corresponding position to ablate the solder strip. In the preheated state, the solder strip is easier to ablate, the ablation process is smoother, and the required energy and time are correspondingly reduced.

[0059] For example, the heating plate preheating method involves placing the stacked battery strings on a heated plate, where heat is conducted through the plate to raise the temperature of the battery strings; the hot air circulation device uses a fan to blow heated air onto the battery strings, ensuring uniform heating; and infrared heating utilizes the thermal effect of infrared rays to directly heat the battery strings. The preheating equipment heats the battery strings according to preset temperature and time parameters to ensure that the battery strings reach a suitable temperature range.

[0060] In this embodiment, solder ribbon melting is achieved with lower energy input, which reduces heat dissipation and its impact on surrounding normal cells. This avoids damage to the internal structure and electrode materials of the cells caused by high temperatures, ensuring the performance and quality of surrounding cells and improving the overall performance and reliability of the entire stacked cell string after repair.

[0061] In one embodiment, such as Figure 5 As shown, the system also includes a miniature pressure head array 5 for melting the conductive adhesive between the solder ribbon and the battery cell after the battery string is preheated and before the solder ribbon is melted. The miniature pressure head array 5 is connected to the battery string preheating device 4 and the solder ribbon melting device 2.

[0062] Conductive adhesive is an adhesive that exhibits certain electrical conductivity after curing or drying. In a battery string, it is used to fill the gap between the solder ribbon and the battery cell, enhancing the electrical and mechanical connections between them. The micro-pressure head array 5 is a device composed of multiple micro-pressure heads arranged in a specific pattern. Each micro-pressure head can work independently or collaboratively, processing a specific area by applying pressure and / or heat. In this embodiment, the micro-pressure head array 5 is used to melt the conductive adhesive between the solder ribbon and the battery cell. For example, the curing temperature of the conductive adhesive can be, for example, 100℃-130℃, and the viscosity can be, for example, 300 mPa·s-1000 mPa·s.

[0063] Specifically, during the battery string rework process, after the battery string is preheated by the preheating equipment, its temperature reaches a preset suitable range. At this time, the physical properties of the conductive adhesive between the solder ribbon and the battery cell change due to the increased temperature, such as a decrease in viscosity and hardness. However, the solder ribbon and the battery cell are still connected together by the conductive adhesive.

[0064] To facilitate smoother melting of the solder ribbon and minimize damage to the solar cells during the melting process, the conductive adhesive between the solder ribbon and the solar cells needs to be melted first. This is where the micro-pressure head array 5 comes into play. Each micro-pressure head in the array 5 is equipped with a heating element and a pressure control device. The heating element heats the micro-pressure head as needed to reach a specific temperature, thereby accelerating the melting process of the conductive adhesive. The pressure control device precisely controls the pressure applied by the micro-pressure head to the conductive adhesive, ensuring that the adhesive is melted evenly and effectively while avoiding excessive pressure damage to the solar cells and solder ribbon.

[0065] During operation, the micro-indenter array 5 precisely moves to the location of the conductive adhesive between the solder strip and the solar cell, based on the defect cell location information provided by the defect detection device 1. Then, the heating element begins to heat the micro-indenters, while the pressure control device applies appropriate pressure to ensure full contact between the micro-indenters and the conductive adhesive. Under the combined action of heat and pressure, the conductive adhesive gradually melts, vaporizes, or decomposes, thereby achieving the dissolution of the conductive adhesive.

[0066] In this embodiment, the preheated conductive adhesive is more easily melted by the micro pressure head array 5, requiring relatively less energy and pressure. This reduces thermal and mechanical damage to the battery cells caused by high temperature and high pressure during the solder strip melting process, protecting the performance and structural integrity of the battery cells and improving the overall quality of the battery string after repair.

[0067] In one embodiment, such as Figure 6 As shown, the system also includes a temperature detection device 6 for detecting the preheating temperature of the stacked battery strings. The temperature detection device 6 is connected to the battery string preheating device 4 and the solder strip melting device 2.

[0068] The preheating temperature is the temperature reached by the stacked battery strings after being heated by the battery string preheating equipment 4 during processes such as battery string rework to improve subsequent processing conditions (e.g., solder strip melting, conductive adhesive treatment). A suitable preheating temperature helps improve the operational efficiency and quality of subsequent processes. The temperature detection equipment 6 is used to measure the preheating temperature of the stacked battery strings. It can accurately sense the surface temperature of the battery strings and convert the temperature information into a readable signal (such as an electrical signal) so that operators or control systems can understand the preheating status of the battery strings.

[0069] Specifically, during the rework process of stacked battery strings, when defective battery cells need to be processed, the battery string preheating device 4 is usually used to preheat the battery string first. During the preheating process, in order to ensure that the battery string reaches a suitable temperature so that subsequent operations such as solder strip melting and conductive adhesive melting can be carried out smoothly, the temperature detection device 6 is used to monitor the preheating temperature in real time.

[0070] Temperature detection equipment typically consists of a temperature sensor, signal processing circuitry, and display device. The temperature sensor is the core component, and common types include thermocouples and resistance temperature detectors (RTDs). Thermocouples utilize the thermoelectric effect between two different metals to measure temperature, offering advantages such as a wide measurement range and fast response. RTDs, on the other hand, measure temperature based on the characteristic that the resistance of a metal conductor changes with temperature, providing higher measurement accuracy.

[0071] During the battery string preheating process, temperature sensors are placed on or near the surface of the battery string to accurately sense its temperature. The sensors convert the detected temperature signal into an electrical signal, which is then transmitted to the signal processing circuit. The signal processing circuit amplifies, filters, and linearizes the electrical signal to meet the requirements for subsequent display or transmission. Finally, the processed temperature signal is displayed on a display device, allowing operators to visually observe the preheating temperature of the battery string.

[0072] In this embodiment, the preheating temperature is precisely controlled by the temperature detection device 6, which avoids the need for repeated heating or adjustment of process parameters due to excessively high or low preheating temperatures. Once the battery string reaches the preset temperature, subsequent operations can be performed immediately, reducing waiting time in the production process and improving production efficiency.

[0073] In one embodiment, such as Figure 7 As shown, the welding strip ablation device 2 includes: a laser source 21 for emitting laser; and a laser adjustment device 22 for adjusting the transmission direction of the laser so that the laser is focused on the welding strip.

[0074] The laser source 21 is a device capable of generating laser light, serving as the energy output source for the solder ribbon ablation device 2. Laser light possesses characteristics such as high energy density, good directionality, and good monochromaticity, providing sufficient energy for solder ribbon ablation. The laser adjustment device 22 is a combination of components used to change the laser transmission direction and focus the laser at a specific location on the solder ribbon. By adjusting the laser's transmission path and focusing state, it ensures that the laser accurately acts on the solder ribbon, achieving effective ablation.

[0075] Specifically, in the rework process of stacked solar cells, when a defective cell is identified and needs to be replaced, the solder ribbon ablation device 2 comes into play. The laser source 21 is the core energy source of the entire device; it generates laser light through a specific physical process (such as stimulated emission). Different laser sources 21 vary in wavelength, power, and stability, and a suitable laser source 21 can be selected based on the material and thickness of the solder ribbon and the ablation requirements. For example, for some thinner solder ribbons, a laser source 21 with relatively lower power but higher focusing accuracy may be needed to avoid over-ablation and damage to surrounding solar cells.

[0076] The laser adjustment device 22 is responsible for precise control of the laser. It typically consists of optical components such as a reflector and a focusing lens. The reflector can change the transmission direction of the laser; by adjusting the angle of the reflector, the laser can accurately target the weld strip to be melted. The focusing lens is used to focus the laser beam into a very small spot, increasing the laser's energy density. The focal length and position of the focusing lens can be adjusted according to the specific conditions of the weld strip to ensure that the laser forms a sufficiently high energy density on the surface of the weld strip, thereby quickly and effectively melting the weld strip.

[0077] In actual operation, the solder strip ablation device 2 works in conjunction with the defect detection device 1 and the battery string positioning device. The defect detection device 1 first determines the location of the defective battery cell and transmits the relevant information to the solder strip ablation device 2. The battery string positioning device ensures that the battery string maintains a stable position during the ablation process. Based on the received information, the solder strip ablation device 2 focuses the laser onto the solder strip connected to the defective battery cell through the laser adjustment device 22. The laser source 21 emits a high-energy laser, which melts or vaporizes the solder strip in a short time, thus achieving the ablation of the solder strip.

[0078] For example, there can be multiple laser light sources 21. That is, in the case of multiple defective solar cells, the solder strips of each defective solar cell can be ablated simultaneously based on multiple laser light sources 21 to improve efficiency.

[0079] In this embodiment, the laser adjustment device 22 can precisely adjust the transmission direction and focusing state of the laser, ensuring that the laser is accurately focused on the solder strip and avoiding accidental damage to surrounding normal battery cells. This high-precision ablation method can guarantee the performance and quality of the battery string after repair and reduce secondary defects caused by inaccurate ablation.

[0080] In one embodiment, such as Figure 8 As shown, the transfer device 3 includes a transfer arm 31 and a suction cup 32 fixed to the end of the transfer arm 31.

[0081] Among them, the transfer arm 31 is one of the core components of the transfer device 3. It is usually composed of a mechanical structure and has multiple degrees of freedom (such as rotation, extension, pitch, etc.). It can flexibly change its position and posture, thereby moving the suction cup 32 to the designated target position to realize the gripping and transfer of battery strings or battery cells.

[0082] The suction cup 32 is a component fixed to the end of the transfer arm 31. It uses the principle of negative pressure to adsorb battery strings or battery cells, allowing the transfer arm 31 to stably grasp and transport them. The material and structure of the suction cup 32 are designed according to the characteristics of the adsorbed object (such as surface flatness, material, etc.) to ensure the reliability and stability of the adsorption.

[0083] Specifically, the transfer equipment 3 plays a crucial role in the production or rework of stacked battery strings. After the battery string completes specific processing steps (such as preheating, solder strip melting, etc.) at a certain station, the transfer equipment 3 begins to work.

[0084] The transfer arm 31 moves according to a preset program and instructions through its internal drive system (such as a motor and reducer) and transmission mechanism (such as gears and chains). It can move freely in three-dimensional space and accurately position itself at the workstation where the battery string is located. For example, in the horizontal direction, the transfer arm 31 can extend and retract to adjust the distance from the battery string; in the vertical direction, it can move up and down to adapt to workstations of different heights; at the same time, the transfer arm 31 can also rotate to adjust the suction angle of the suction cup 32, ensuring that the suction cup 32 can fully contact the surface of the battery string.

[0085] Once the transfer arm 31 moves to the appropriate position, the suction cup 32 fixed to its end begins to operate. The suction cup 32 generates negative pressure through a vacuum generator, creating an environment inside the suction cup 32 with a pressure lower than the external atmospheric pressure. When the suction cup 32 contacts the surface of the battery string, the battery string is firmly adhered to the suction cup 32 under the influence of the pressure difference. The transfer arm 31 then moves the suction cup 32, with the battery string attached, to the next target station, such as a testing station, assembly station, or storage station. Upon reaching the target station, the vacuum generator stops operating, the negative pressure inside the suction cup 32 disappears, and the battery string is stably placed in the target position.

[0086] In this embodiment, the transfer device 3 can quickly and accurately transfer battery strings between different workstations, reducing the time and labor intensity of manual handling. Compared with manual handling, the transfer device 3 operates faster and with higher precision, which can greatly shorten the production cycle and improve production efficiency.

[0087] In one embodiment, the suction cup is an adjustable suction cup, and the transfer arm is provided with a suction adjustment device, which is electrically connected to the suction cup.

[0088] Among them, the adjustable suction cup is a type of suction cup that can change the magnitude of the suction force according to actual needs. Through a special internal design or structure, combined with an external adjustment device, it achieves precise control of the suction force to adapt to objects with different weights, materials, and surface characteristics.

[0089] The suction adjustment device is installed on the transfer arm and is electrically connected to the adjustable suction cup. It can receive operating commands or adjust the suction force of the suction cup according to preset parameters to ensure that the suction cup can stably and safely adsorb and transport objects.

[0090] Specifically, in the production or rework process of stacked battery strings, the transfer equipment 3 plays a crucial role in efficiently and accurately transferring the battery strings between different workstations. Once a battery string has completed processing at one workstation, the transfer arm begins operation.

[0091] The transfer arm, powered by its internal drive system (such as motors and reducers) and transmission mechanism (such as gears and chains), moves flexibly in three-dimensional space according to a preset program and instructions. It can precisely locate the battery string and adjust its angle according to the orientation of the battery string, allowing the suction cup to approach the battery string at a suitable angle.

[0092] An adjustable suction cup is fixed to the end of the transfer arm. As the suction cup approaches the battery string, the suction adjustment mechanism kicks in. This mechanism integrates sensors, a controller, and an actuator. The sensors monitor the contact status between the suction cup and the battery string, as well as the strength of the suction force, in real time.

[0093] For example, when adsorbing thinner battery strings, the suction adjustment device will reduce the suction force of the suction cup to avoid deformation or damage to the battery strings due to excessive suction force; while when adsorbing heavier or rougher battery strings, the suction adjustment device will increase the suction force of the suction cup to ensure that the battery strings can be stably adsorbed.

[0094] Once the suction cups have properly engaged the battery string, the transfer arm smoothly moves it to the next target station. Upon reaching the target station, the suction adjustment device activates again, gradually reducing the suction force of the suction cups to ensure the battery string is placed stably in the target position, completing one transfer cycle.

[0095] In this embodiment, the combined use of the adjustable suction cup and the suction adjustment device allows for precise adjustment of the suction power according to the actual condition of the battery string. This avoids damage to the battery string caused by excessive suction, such as scratching the surface of the battery cells or damaging the internal structure of the battery cells. At the same time, it also prevents the battery string from falling off during transportation due to insufficient suction, thus improving the safety and reliability of the transportation process.

[0096] In one embodiment, the suction cup surface is provided with a flexible buffer layer.

[0097] The flexible buffer layer is made of an elastic material with a high coefficient of friction and high temperature resistance. The surface of the flexible buffer layer has a microstructure texture, which can increase the friction when in contact with the defective battery cell, and at the same time buffer the impact force that may be generated during the transportation process, preventing the defective battery cell from slipping or being damaged during transportation.

[0098] In one embodiment, the system further includes a cell surface treatment device disposed on the movement path of the stacked cell string after the defective cell transfer.

[0099] The movement path of the stacked solar cell strings refers to the route they take when transferred between production or rework equipment. This path is typically defined by a conveyor system (such as a conveyor belt or guide rail), along which the strings move from one workstation to the next. The cell surface treatment equipment is located along this movement path and is used to perform specific treatments on the cell surfaces. These treatments may include cleaning the cell surfaces, removing impurities, and improving surface properties (such as increasing surface roughness to enhance adhesion), to ensure the cells achieve good performance and quality during subsequent assembly or processing.

[0100] After the defective solar cells are transferred, when the stacked solar cell string accurately reaches the processing position, the solar cell surface treatment equipment will treat the surface of the solar cells. Residual tin dross on the surfaces of adjacent separated solar cells will be cleaned with a neutral solvent (pH: 6.5-7.5), and surface properties will be restored through plasma activation. After processing, the stacked solar cell string continues along the moving path to the next station.

[0101] In this embodiment, by cleaning and activating the surface of the solar cells, impurities and contaminants can be effectively removed, improving the physical and chemical properties of the cell surface. This helps improve the electrical connection performance between the cells, reduces contact resistance, and thus improves the overall output power and energy conversion efficiency of the stacked solar cell string.

[0102] In a specific embodiment, the specific operation process of the above system includes: detecting the battery string through defect detection equipment and EL (Electroluminescence) detection, identifying defects in the battery cells (such as microcracks, broken grids, and black spots) in the stacked battery string, and marking the coordinates of the defect locations.

[0103] Specifically, stacked battery strings are placed on a rework station, and a defect detection device is used to accurately locate the battery cells that need repair and the type of repair based on the marked positions on the battery strings. The feedback control device then performs the corresponding rework operation. The defect detection device can be, for example, a high-resolution CCD camera.

[0104] The solder ribbon ablation equipment (wavelength 1064nm, power 10-20W) is used to perform non-contact local ablation on the solder ribbon of the defective solar cell, separating the defective solar cell from the adjacent solar cell.

[0105] Subsequently, for battery strings without conductive adhesive, the required preheating temperature of the battery string can be set, and the battery string preheating equipment can start heating to preheat the battery string. The temperature detection equipment feeds back to the control equipment in real time (temperature difference ±3℃). When the temperature reaches the set temperature, the control equipment drives the solder strip melting equipment to weld and melt the damaged position.

[0106] For battery strings with conductive adhesive: Set the required preheating temperature for the battery string, start heating the battery string using the battery string preheating device, use a micro pressure head array to flatten the battery and keep it warm for a set time to melt the conductive adhesive, and after the conductive adhesive is melted, control the device to drive the welding strip melting device to weld and melt the damaged area.

[0107] The target solar cells are adsorbed using a transfer device and slowly transported at an angle of <6° along the stacking direction (to prevent fragmentation). Residual tin dross on the surfaces of adjacent cells after separation is cleaned with a neutral solvent (pH: 6.5-7.5) using a solar cell surface treatment device, and surface properties are restored through plasma activation. The transfer device can be, for example, a vacuum chuck clamp.

[0108] Then, the prepared new cells can be positioned according to the original overlap (0.2-0.5mm), and the fill factor (FF) recovery rate of the repaired cell string can be verified by using an IV tester to be ≥95% and the microcrack propagation rate <1%.

[0109] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0110] The embodiments described above are merely illustrative of several implementations of this utility model, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. A rework system for stacked battery strings, characterized in that, The system includes: A defect detection device for detecting defective cells from multiple cells in a stacked battery string; A solder strip ablation device for ablating the solder strip between the defective battery cell and an adjacent battery cell; In the event that the solder strip melts, a transfer device is used to transfer the defective battery cell.

2. The system according to claim 1, characterized in that: The weld strip ablation equipment is connected to the defect detection equipment and the transfer equipment; or The system also includes control equipment; The control device is connected to the defect detection device, the weld strip ablation device, and the transfer device.

3. The system according to claim 1, characterized in that, The system also includes: A battery string preheating device for preheating the stacked battery string before the solder strip is melted.

4. The system according to claim 3, characterized in that, The system also includes: A miniature pressure head array that melts the conductive adhesive between the solder ribbon and the battery cell after the battery string is preheated and before the solder ribbon is melted.

5. The system according to claim 3, characterized in that, The system also includes: A temperature detection device for detecting the preheating temperature of the stacked battery string.

6. The system according to claim 1, characterized in that, The welding strip ablation equipment includes: Laser source that emits laser light; A laser adjustment device that adjusts the transmission direction of the laser to focus the laser onto the welding strip.

7. The system according to claim 1, characterized in that, The transfer device includes a transfer arm and a suction cup fixed to the end of the transfer arm.

8. The system according to claim 7, characterized in that, The suction cup is an adjustable suction cup, and the transfer arm is equipped with a suction adjustment device, which is electrically connected to the suction cup.

9. The system according to claim 8, characterized in that, The suction cup surface is provided with a flexible buffer layer.

10. The system according to claim 1, characterized in that, The system also includes: A cell surface treatment device is installed on the movement path of the stacked cell string after the defective cell is transferred.

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