An off-line repair system for photovoltaic modules

Abstract

The utility model discloses a photovoltaic module off-line type repair system, it includes the front EL detection machine, the material conveying line at the front EL detection machine is the reversing conveying line with the reversing function, and the reversing output side is provided with the lifting stack line body, and the output side of lifting stack line body is docked transfer station, can utilize AGV dolly to realize with the material of repair area's material to and fro, the utility model discloses adopting off-line type repair design, removes the defective product from the main line and carries out repair, has improved the reliability of photovoltaic module production line normal operation.

Description

[Technical Field]

[0001] This utility model belongs to the technical field of photovoltaic module production line, and in particular relates to an offline repair system for photovoltaic modules. [Background Technology]

[0002] Photovoltaic (PV) modules are power generation components that convert solar energy into electrical energy. The entire manufacturing process of PV modules involves multiple steps, including stringing, lamination, microscopic inspection, pre-lamination EL inspection, lamination, edge trimming, visual inspection, framing, junction box installation, potting, curing, backside cleaning, insulation withstand voltage testing, frontside cleaning, IV testing, post-lamination EL inspection, final inspection, sorting, and packaging. In the PV module manufacturing process, to improve yield and reduce defective products, pre-lamination rework is a necessary step to address anomalies such as microcracks, fragments, and poor soldering.

[0003] In existing technologies, rework during the assembly process of photovoltaic modules is mostly done online. For example, patent CN106653943B discloses an assembly line for manufacturing photovoltaic modules, and patent CN219979583U discloses a highly versatile online photovoltaic module rework device. However, this online rework station design has the following drawbacks:

[0004] (1) Setting up a rework station and configuring a conveyor line directly on the photovoltaic module assembly line increases the overall footprint of the photovoltaic module assembly line and the number of personnel on the assembly line.

[0005] (2) The number of online rework stations is limited, and rework generally takes a long time. When there are a large number of defective products, all rework stations are occupied by NG defective products, and the newly appearing defective products may accumulate, causing the entire line to stop.

[0006] (3) Online rework may lead to secondary defects due to time pressure, such as hasty welding or incomplete cleaning.

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

[0008] The main purpose of this utility model is to provide an offline repair system for photovoltaic modules. By adopting an offline repair design, defective products are removed from the main line for repair, thereby improving the reliability of the normal operation of the photovoltaic module production line.

[0009] This utility model achieves the above-mentioned objective through the following technical solution: an offline repair system for photovoltaic modules, which includes a front EL inspection machine, wherein the material conveying line at the front EL inspection machine is a reversing conveying line with a reversing function, and a first lifting stacking line is provided on its reversing output side, and the output side of the first lifting stacking line is connected to the transfer station.

[0010] Furthermore, it includes an adhesive application area, with the front EL inspection machine located at the tail end of the adhesive application area; the adhesive application area includes, in sequence along the material flow direction, a combination of a tape applicator, a small piece long-side strip placement machine, a short-side strip placement machine, a second-layer adhesive film laying machine, a backing plate cutting and laying machine, a sheet assembly machine, or a lead wire bending and high-temperature cloth laying machine.

[0011] Furthermore, a second glass feeding area is provided at the reversing docking point of the laminating machine; an edge sealing machine is provided downstream of the front EL inspection machine.

[0012] Furthermore, the first lifting and stacking line uses AGV trolleys to dock materials at the transfer station to facilitate material exchange with the rework area.

[0013] Furthermore, the first lifting stacking line includes a frame, a drive unit disposed on the frame, a support that is driven by the drive unit to move up and down, and several layers of buffer conveyor lines disposed on the support in layers.

[0014] Furthermore, the support is equipped with sensors at the locations of each layer of the buffer conveyor line to monitor whether there is material on the buffer conveyor line.

[0015] Furthermore, it also includes a control system, which is electrically connected to the sensor and controls the start and stop of the buffer conveyor line, whether the reversing conveyor line performs a reversing operation, and the start and stop of the conveying operation; the control system is communicatively connected to the AGV trolley.

[0016] Furthermore, the control system is configured to: when the sensor detects that the number of defective products buffered in the first lifting stack line reaches a set quantity, send a first signal to the AGV trolley to pick up the material, and when it receives a second signal from the AGV trolley requesting unloading, control the buffer conveyor line to output the material.

[0017] Furthermore, the AGV is configured to automatically move to the output side of the first lifting stack line when it receives the first signal from the control system, and send the second signal to the control system after moving into position.

[0018] Furthermore, the control system is also configured to: when the front EL inspection machine detects a defective product, control the reversing conveyor line to perform a reversing action and transport the defective product to the first lifting stacking line.

[0019] Compared with existing technologies, the beneficial effects of this utility model's offline photovoltaic module repair system are as follows: By connecting a first lifting and stacking line to the pre-lamination EL inspection machine, and setting the conveyor line at this station as a reversing conveyor line with a reversing function, defective products detected by the pre-lamination EL inspection machine are output to the main line using the reversing conveyor line. The first lifting and stacking line is used to buffer defective products. When the buffer reaches a set quantity, AGVs are used to collect and transport them to an offline repair area for centralized repair, thus forming an offline photovoltaic module repair system. The offline repair system has the following advantages:

[0020] (1) It can avoid interruption of main production line and improve overall efficiency: Defective products are removed from the main line, the main line can continue to operate, ensure normal output and production line cycle time, and improve the reliability of smooth operation of the production line; it can effectively avoid the entire line from stopping due to rework backlog;

[0021] (2) It enables flexible allocation of resources and reduces overall costs: independent rework areas can concentrate manpower, equipment and tools, eliminating the need to repeatedly allocate resources for each workstation; rework workstations can be added, removed or adjusted as needed to adapt to the fluctuations in defect rates of different batches;

[0022] (3) Reduce product quality risks: Online rework may lead to secondary defects due to time pressure, while offline rework can thoroughly analyze the causes and standardize operations;

[0023] (4) It can optimize the production cycle balance: online rework will lengthen the cycle time of a specific workstation, which may become a production bottleneck; while offline rework can maintain the consistency of the cycle time of each workstation on the main line. [Attached Image Description]

[0024] Figure 1 This is a top view schematic diagram of an embodiment of the present utility model;

[0025] Figure 2 This is a top view of the welding area in an embodiment of the present invention;

[0026] Figure 3 This is a top view of the small block long side strip placement machine in an embodiment of this utility model;

[0027] Figure 4 This is a side view of the first lifting stacking line in an embodiment of the present invention;

[0028] Figure 5This is a schematic diagram showing the connection between the control system and the AGV trolley, the reversing conveyor line, and the first lifting and stacking line in this embodiment of the present invention.

[0029] The numbers in the diagram represent:

[0030] 100- Photovoltaic module production line;

[0031] 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;

[0032] 20-Adhesive application area; 21-Tape applicator; 22-Small piece long-side strip placement machine; 221-Component conveyor line; 222-Strip cutting and feeding module; 223-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-Backsheet cutting and laying machine; 26-Sheet assembly machine; 27-Lead wire bending and high-temperature cloth laying machine; 28-Front EL inspection machine; 29-Sealing. Side machine; 210-Fifth lifting and stacking line; 211-Second lifting and stacking line; 212-Third lifting and stacking line; 213-Fourth lifting and stacking line; 214-First lifting and stacking line; 2141-Frame; 2142-Driver; 2143-Bracket; 2144-Buffer conveyor line; 2145-Sensor; 215-AGV trolley; 30-Lamination area; 40-First glass loading area; 50-Second glass loading area; 60-Control system. 【Detailed Implementation Methods】

[0033] Example 1:

[0034] Please refer to Figures 1-5 This embodiment is a photovoltaic module production line 100, which includes a welding area 10, a bonding and laying area 20 and a laminating 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 bonding and laying area 20 is provided with a second glass feeding area 50.

[0035] 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 the Y-opposite side of the first conveyor line 11 and output battery strings along the Y direction, a plurality of sorting machines 13 that are disposed 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 along the X-opposite direction, and a battery string end welding machine 15 disposed at the tail end of the first conveyor line 11.

[0036] 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 multiple combinations of the following: 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, and a lead wire bending and high-temperature laying machine 27, 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. The tape applicator 21, the small long-side strip placement machine 22, the short-side strip placement machine 23, the second-layer adhesive film laying machine 24, the backsheet cutting and laying machine 25, the laminating machine 26, and the lead wire bending and high-temperature laying machine 27 can be flexibly combined and configured according to the process requirements of different types of photovoltaic modules. Among them: Tape applicator 21 is used to apply tape to designated locations and fix the battery string to a glass plate; Small piece long side strip placement machine 22 is mainly used to place two long side EVA strips at designated locations on the long side and place small EVA pieces at three lead wire locations; Short side strip placement machine 23 is mainly used to place two short side EVA strips at designated locations on the short side; Second-layer adhesive film laying machine 24 is mainly used to cut and lay two layers of EVA adhesive film; Backplate cutting and laying machine 25 is mainly used to cut and lay backplate TPT; Lamination machine 26 is mainly used to pick up the second layer of glass output from the second glass feeding area 50 and complete the lamination operation of the second layer of glass with the first layer of glass; Lead wire bending and high-temperature cloth placement machine 27 is mainly used to apply high-temperature cloth at three lead wire locations and then bend and flatten the lead wires for subsequent lamination operations.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] 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.

[0041] 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.

[0042] The end section of the pasting and laying area 20 is also equipped with a front EL inspection machine 28 and an edge sealing machine 29.

[0043] 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 fifth 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.

[0044] 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.

[0045] To implement an offline rework system, this embodiment configures the conveyor line at the front EL inspection machine 28 as a reversing conveyor line with a reversing function. A first lifting and stacking line 214 is provided on the X-direction opposite side of the front EL inspection machine 28 to buffer defective components. This embodiment also includes an AGV trolley 215. When the number of defective products buffered by the first lifting and stacking line 214 reaches a set value, the AGV trolley 215 removes the defective products and transports them to the rework area for offline centralized rework.

[0046] The first lifting stacking line 214 includes a frame 2141, a drive unit 2142 disposed on the frame 2141, a support 2143 driven by the drive unit 2142 to move up and down, and several layers of buffer conveyor lines 2144 disposed on the support 2143.

[0047] The support 2143 is equipped with a sensor 2145 at the position corresponding to each layer of the buffer conveyor line 2144 to monitor whether there is material on the buffer conveyor line 2144.

[0048] The photovoltaic module production line 100 also includes a control system 60, which is electrically connected to the sensor 2145 and controls the start and stop of the buffer conveyor line 2144, whether the reversing conveyor line performs a reversing operation, and the start and stop of the conveying operation; the control system 60 is communicatively connected to the AGV trolley 215.

[0049] The control system 60 is configured to: when the sensor 2145 detects that the number of defective products buffered in the first lifting stack line 214 reaches a set number, it sends a first signal to the AGV trolley 215 to pick up the material, and when it receives a second signal from the AGV trolley 215 requesting unloading, it controls the buffer conveyor line 2144 to output the material.

[0050] The AGV trolley 215 is configured to automatically move to the output side of the first lifting stack line 214 when it receives the first signal from the control system 60, and send the second signal to the control system 60 after moving into position.

[0051] The control system 60 is configured to: when the front EL inspection machine 28 detects a defective product, control the reversing conveyor line to perform a reversing action and transport the defective product to the first lifting stacking line 214.

[0052] 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.

[0053] 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. An offline repair system for photovoltaic modules, characterized in that: Includes a front EL inspection machine, wherein the material conveying line at the front EL inspection machine is a reversing conveying line with a reversing function, and a first lifting stacking line is provided on its reversing output side, and the output side of the first lifting stacking line is connected to the transfer station.

2. The photovoltaic module offline repair system as described in claim 1, characterized in that: It includes an adhesive application area, with the front EL inspection machine located at the tail end of the adhesive application area; the adhesive application area includes, in sequence along the material flow direction, a combination of a tape applicator, a small piece long side strip placement machine, a short side strip placement machine, a second adhesive film laying machine, a backing plate cutting and laying machine, a sheet assembly machine, or a lead wire bending and high-temperature cloth laying machine.

3. The photovoltaic module offline repair system as described in claim 2, characterized in that: The glass laminator is equipped with a second glass feeding area for reversing the connection; a sealing machine is located downstream of the front EL inspection machine.

4. The photovoltaic module offline repair system as described in claim 1, characterized in that: The first lifting and stacking line uses AGV trolleys to dock materials at the transfer station to achieve material exchange with the rework area.

5. The photovoltaic module offline repair system as described in claim 4, characterized in that: The first lifting stacking line includes a frame, a drive unit mounted on the frame, a support that is driven by the drive unit to move up and down, and several layers of buffer conveyor lines arranged vertically on the support.

6. The photovoltaic module offline repair system as described in claim 5, characterized in that: The support frame is equipped with sensors at the locations of each layer of the buffer conveyor line to monitor whether there is material on the buffer conveyor line.

7. The photovoltaic module offline repair system as described in claim 6, characterized in that: It also includes a control system, which is electrically connected to the sensor and controls the start and stop of the buffer conveyor line, whether the reversing conveyor line performs a reversing operation, and the start and stop of the conveying operation; the control system is communicatively connected to the AGV trolley.

8. The photovoltaic module offline repair system as described in claim 7, characterized in that: The control system is configured such that when the sensor detects that the number of defective products buffered in the first lifting stack line reaches a set quantity, it sends a first signal to the AGV to pick up the material, and upon receiving a second signal from the AGV requesting unloading, it controls the buffer conveyor line to output the material.

9. The photovoltaic module offline repair system as described in claim 8, characterized in that: The AGV is configured to automatically move to the output side of the first lifting stack line when it receives the first signal from the control system, and send the second signal to the control system after moving into position.

10. The photovoltaic module offline repair system as described in claim 8, characterized in that: The control system is also configured to: when the front EL inspection machine detects a defective product, control the reversing conveyor line to perform a reversing action and transport the defective product to the first lifting stacking line.

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