Lead straightening module and small piece placement device

Abstract

The utility model discloses a kind of lead correction module and small piece placing device, small piece placing device includes visual positioning unit, lead correction unit and small piece carrying and placing unit;Lead correction unit includes second support beam, Z-axis drive module fixed on second support beam, third support beam driven by Z-axis drive module and moving up and down and lead correction module movably arranged on third support beam along X direction;Lead correction module includes first motor, horizontal support plate driven by first motor and moving along X direction and being provided with correction operation window in middle part, first straightening die and second straightening die being arranged on horizontal support plate and being located on the two sides of correction operation window Y direction, first pressing die and second pressing die being arranged on horizontal support plate and being located on the two sides of correction operation window X direction.The utility model can effectively solve the battery string displacement problem caused by lead position correction stress.

Description

Technical Field

[0001] This utility model belongs to the technical field of photovoltaic module production equipment, and in particular relates to a lead wire straightening module and a small block placement device. Background Technology

[0002] In the manufacturing process of photovoltaic modules, there is a gap in the EVA film at the lead connection location to allow the lead to pass through and be exposed. To fill this gap, a small piece is usually used to cover it, preventing the molten material from being squeezed out of the gap after the film melts during lamination. When installing the small piece, it needs to pass through the vertical leads on the photovoltaic module. However, the vertical leads on the photovoltaic module can have various orientations and are not always perfectly straight. Therefore, the lead needs to be aligned during the installation of the small piece so that it can smoothly pass through the perforation in the small piece before being attached to the EVA film surface.

[0003] Existing patent CN115557043B discloses an integrated device and process for placing and labeling insulating materials for photovoltaic modules. This device realizes lead wire correction, small piece feeding, handling, and placement. However, in this device, the correction operation of the busbar leads is prone to causing the risk of cell string displacement. Because the distance between the busbars and the cell strings inside the photovoltaic module is extremely small (usually only millimeters), and the cell strings are made of thin silicon wafers connected in series by solder strips, the overall rigidity is poor and there is no strong fixed constraint. When the existing lead wire correction mechanism applies lateral correction force to the leads, it is easy to touch the cell strings due to the limited operating space, causing the cell strings to deviate from the preset position. This not only affects the accurate placement of subsequent small pieces, but may also damage the electrical connection of the cell strings, causing the module power to decrease or fail.

[0004] Therefore, it is necessary to provide a new lead wire straightening module and a small block placement device to solve the above-mentioned technical problems. Utility Model Content

[0005] The main purpose of this utility model is to provide a lead wire straightening module and a small block placement device, which can effectively solve the problem of battery string displacement caused by force during lead wire position straightening.

[0006] This utility model achieves the above-mentioned objective through the following technical solution: a lead wire straightening module, comprising a first motor, a first support plate driven by the first motor to move along the X direction, a horizontal support plate fixed at the bottom end of the first support plate and having a straightening operation window in the middle, a first straightening module and a second straightening module disposed on the horizontal support plate and located on both sides of the straightening operation window in the Y direction, and a first pressing module and a second pressing module disposed on the horizontal support plate and located on both sides of the straightening operation window in the X direction.

[0007] Furthermore, both the first straightening module and the second straightening module include a first cylinder fixed on the horizontal support plate and a straightening fork plate that moves along the Y direction driven by the first cylinder; when the two straightening forks in the first straightening module and the second straightening module come close to each other, they are stacked together.

[0008] Furthermore, the free end of the corrective fork is provided with a Y-direction extending lead wire limiting groove; one end of the lead wire limiting groove is an open structure.

[0009] Furthermore, the first clamping module and the second clamping module respectively clamp the root of the two bent leads at the same location.

[0010] Furthermore, both the first pressing module and the second pressing module include a second cylinder fixed on the horizontal support plate and a pressing plate that is driven by the second cylinder to move in the X direction.

[0011] Another objective of this utility model is to provide a small block placement device, which includes: The visual positioning unit is used to visually locate the position of the leads on the photovoltaic module. The lead wire correction unit, guided by the visual positioning unit, corrects the position of the leads on the photovoltaic module, and includes a second support beam, a Z-axis drive module fixed on the second support beam, a third support beam driven by the Z-axis drive module to move up and down, and a lead wire correction module movably arranged on the third support beam along the X direction as described above. The small piece handling and placement unit picks up small pieces of material and places them at the photovoltaic module lead position; The small piece handling and placement unit and the visual positioning unit are located on both sides of the lead wire correction unit in the Y direction.

[0012] Furthermore, the visual positioning unit includes a first support beam, a plurality of cameras spaced apart along the X direction on the first support beam, and a light source that illuminates a designated area on the photovoltaic module.

[0013] Furthermore, the lead wire straightening unit includes a second support beam, a Z-axis drive module fixed on the second support beam, and a third support beam driven by the Z-axis drive module to move up and down; multiple lead wire straightening modules are movably arranged on the third support beam along the X direction; a first rack extending along the X direction is provided on the third support beam, and the first motor is fixed on the first support plate and has a first drive gear meshing with the first rack at its movable end.

[0014] Furthermore, the small piece handling and placement unit includes a YZ drive module, a fourth support beam disposed at the movable end of the YZ drive module, and a plurality of small piece adsorption modules disposed on the fourth support beam along the X direction; the small piece adsorption module includes a second motor, a second support plate driven by the second motor to move along the X direction, a third cylinder fixed on the second support plate, and a suction nozzle module driven by the third cylinder to move up and down; the fourth support beam is provided with a second rack extending along the X direction, and the second motor is fixed on the second support plate with a second drive gear meshing with the second rack at its movable end.

[0015] Furthermore, it also includes a gantry support, on which the visual positioning unit and the guide wire correction unit are adjustablely positioned along the Y direction.

[0016] Compared with the prior art, the advantages of the lead wire straightening module and small block placement device of this utility model are as follows: (1) It can reduce the risk of battery string displacement and ensure the electrical stability of the module. This device innovatively sets up first and second clamping modules in the lead wire straightening module. Before the straightening operation, the clamping plate precisely clamps the root of the lead wire bend, forming a "fixed anchor" for the lead wire. This design can effectively counteract the lateral straightening force applied to the lead wire by the straightening fork plate, and avoid the lead wire from touching the adjacent battery string due to rubbing. It solves the problem of battery string displacement caused by traditional straightening operation from the root, ensures the complete electrical connection of the battery string, significantly reduces the risk of power attenuation caused by structural displacement of the module, and improves the production yield of photovoltaic modules.

[0017] (2) Enhance equipment versatility and adapt to the production of multi-specification modules. The visual positioning unit and the lead wire correction unit are mounted on the gantry bracket with adjustable positions along the Y direction via slide rails. After adjustment, they only need to be locked with fasteners to complete the adaptation. This design allows the equipment to be quickly switched to photovoltaic module production scenarios with different sizes and lead wire spacings without disassembly and reconstruction, greatly shortening the debugging time for specification switching, reducing equipment modification costs, and meeting the current photovoltaic industry's demand for multi-category and flexible production.

[0018] (3) Enables multi-station synchronous operation and improves production efficiency. The vision positioning unit is equipped with three cameras, the lead wire correction unit is equipped with three sets of correction modules, and the small piece handling and placement unit is equipped with three sets of adsorption modules. The three form a "three-station synchronous collaboration" operation mode: the positioning, correction and small piece placement of the three leads on the photovoltaic module can be completed at the same time, which can greatly improve the operation efficiency, effectively match the pace requirements of large-scale mass production, and help enterprises increase production capacity.

[0019] (4) Ensure the accuracy of small piece placement and reduce rework rate. The device adopts a collaborative design of the whole process of "visual positioning - precise correction - anchoring placement": the visual positioning unit first obtains the precise position of the lead wire, the lead wire correction unit completes the correction under the premise of fixing the root of the lead wire, and the small piece handling and placement unit completes the placement based on the corrected precise position. The three form a closed loop control to avoid secondary deviation of the lead wire and ensure that the small piece is accurately placed at the root of the lead wire bend, which significantly reduces the rework cost caused by placement deviation and improves the consistency and reliability of component assembly. Attached Figure Description

[0020] Figure 1 This is a three-dimensional structural diagram of an embodiment of the present utility model; Figure 2 This is a schematic diagram of the lead wire straightening unit in an embodiment of the present invention; Figure 3 This is a partial structural schematic diagram of the lead wire straightening unit in an embodiment of this utility model; Figure 4 This is a schematic diagram of the structure of the small piece handling and placement unit in an embodiment of this utility model; The numbers in the image represent: 100 - Small piece placement device; 200 - Small piece material; 1-Gantry support, 11-Slide rail; 2-Visual positioning unit, 21-First support beam, 22-Camera, 23-Light source; 3- Lead wire straightening unit, 31- Second support beam, 32- Z-axis drive module, 33- Third support beam, 34- Lead wire straightening module, 341- First motor, 342- First support plate, 343- Horizontal support plate, 3431- Straightening operation window, 344- First straightening module, 3441- First cylinder, 3442- Straightening fork plate, 34421- Lead wire limiting groove, 345- Second straightening module, 346- First clamping module, 3461- Second cylinder, 3462- Clamping plate, 347- Second clamping module, 35- First rack, 36- First drive gear; 4-Small piece handling and placement unit, 41-YZ drive module, 42-Fourth support beam, 43-Small piece adsorption module, 431-Second motor, 432-Second support plate, 433-Third cylinder, 434-Suction nozzle module, 44-Second rack, 45-Second drive gear; Detailed Implementation

[0021] Example 1: Please refer to Figures 1-4This embodiment is a small piece placement device 100, which includes a gantry support 1, a visual positioning unit 2 set on the gantry support 1 for visually positioning the position of the lead wire on the photovoltaic module, a lead wire correction unit 3 for correcting the position of the lead wire on the photovoltaic module under the guidance of the visual positioning unit 2, and a small piece handling and placement unit 4 for picking up small pieces of material and placing them at the position of the lead wire of the photovoltaic module.

[0022] The visual positioning unit 2 includes a first support beam 21 mounted on the gantry bracket 1, a plurality of cameras 22 spaced apart along the X direction on the first support beam 21, and a light source 23 illuminating a designated area on the photovoltaic module. In this embodiment, three cameras 22 are provided, each aimed at one of the three locations of the leads on the photovoltaic module.

[0023] The lead wire straightening unit 3 includes a second support beam 31 mounted on the gantry bracket 1, a Z-axis drive module 32 fixed on the second support beam 31, a third support beam 33 driven by the Z-axis drive module 32 to move up and down, and multiple lead wire straightening modules 34 movably mounted on the third support beam 33 along the X direction.

[0024] In this embodiment, three lead straightening modules 34 are provided, each used to align with one of the three lead locations on the photovoltaic module. Each lead straightening module 34 includes a first motor 341, a first support plate 342 driven by the first motor 341 to move along the X direction, a horizontal support plate 343 fixed to the bottom of the first support plate 342 and having a straightening operation window 3431 in the middle, a first straightening module 344 and a second straightening module 345 disposed on the horizontal support plate 343 and located on both sides of the straightening operation window 3431 in the Y direction, and a first clamping module 346 and a second clamping module 347 disposed on the horizontal support plate 343 and located on both sides of the straightening operation window 3431 in the X direction.

[0025] The third support beam 33 is provided with a first rack 35 extending in the X direction, and the first motor 341 is fixed on the first support plate 342 and has a first drive gear 36 that meshes with the first rack 35 at its movable end.

[0026] The first straightening module 344 and the second straightening module 345 have the same structure and both include a first cylinder 3441 fixed on a horizontal support plate 343 and a straightening fork 3442 driven by the first cylinder 3441 to move along the Y direction. The free end of the straightening fork 3442 is provided with a lead wire limiting groove 34421. When the two straightening forks 3442 in the first straightening module 344 and the second straightening module 345 are brought close together, they are stacked together, and the lead wire is constrained at a set position by the lead wire limiting groove 34421.

[0027] In photovoltaic modules, the main body of the busbar is bonded to the gap between two adjacent cell strings using an intermittent bonding method, with its end pointing upwards to form a lead. The gap between the busbar and the cell string inside the photovoltaic module is extremely small (typically only millimeters). When the straightening fork 3442 corrects the position of the lead, due to limited operating space and the lateral constraint force of the straightening fork 3442, the lead is prone to touching the cell string as well. Since the cell string itself is a thin and fragile series structure without strong fixed constraints, it is easily displaced. To solve this technical problem, this embodiment provides a first clamping module 346 and a second clamping module 347, respectively used to clamp the root of two bent leads at the same location. The first clamping module 346 and the second clamping module 347 have the same structure and both include a second cylinder 3461 fixed on a horizontal support plate 343 and a clamping plate 3462 driven by the second cylinder 3461 to move along the X direction. By setting the first clamping module 346 and the second clamping module 347, it is possible to effectively prevent the straightening fork plate 3442 from jerking the lead wires during the correction of the lead wire position, which would cause the battery string to shift and affect the electrical connection of the battery string.

[0028] The small piece handling and placement unit 4 includes a YZ drive module 41 mounted on the gantry bracket 1, a fourth support beam 42 mounted at the movable end of the YZ drive module 41, and multiple small piece adsorption modules 43 mounted on the fourth support beam 42 along the X direction. In this embodiment, three sets of small piece adsorption modules 43 are provided, simultaneously realizing the suction, handling, and placement of three small pieces of material 200. The small piece adsorption module 43 includes a second motor 431, a second support plate 432 driven by the second motor 431 to move along the X direction, a third cylinder 433 fixed on the second support plate 432, and a suction nozzle module 434 driven by the third cylinder 433 to move up and down.

[0029] The fourth support beam 42 is provided with a second rack 44 extending in the X direction, and the second motor 431 is fixed on the second support plate 432 and has a second drive gear 45 that meshes with the second rack 44 at its movable end.

[0030] To accommodate photovoltaic modules of various specifications, in this embodiment, the visual positioning unit 2 and the lead wire correction unit 3 are adjustablely positioned on the gantry bracket 1 along the Y direction. Specifically, the gantry bracket 1 is provided with a slide rail 11 extending along the Y direction, and the first support beam 21 and the second support beam 31 are slidably mounted on the slide rail 11 and locked in place by fasteners after the positions are adjusted.

[0031] The workflow of the small piece placement device 100 in this embodiment includes the following steps: S1. Move the photovoltaic modules into place and correct their positions; S2, Visual positioning unit 2 obtains the position of the lead wire on the photovoltaic module; S3. The lead wire straightening unit 3 straightens the lead wire according to the lead wire position information: the clamping plates 3462 in the first clamping module 346 and the second clamping module 347 respectively clamp the bent roots of the two lead wires at the same position, and then the straightening fork plates 3442 in the first straightening module 344 and the second straightening module 345 move closer to each other to straighten the lead wire to the set position. S4. The small piece handling and placement unit 4 picks up the small piece of material and places it at the lead wire. The lead wire passes through the perforation on the small piece of material 200, and the small piece of material falls to the root of the lead wire bend, completing the placement of the small piece.

[0032] 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 lead wire straightening module, characterized in that, It includes a first motor, a first support plate driven by the first motor to move along the X direction, a horizontal support plate fixed at the bottom of the first support plate and having a correction operation window in the middle, a first straightening module and a second straightening module disposed on the horizontal support plate and located on both sides of the correction operation window in the Y direction, and a first pressing module and a second pressing module disposed on the horizontal support plate and located on both sides of the correction operation window in the X direction.

2. The lead wire straightening module as described in claim 1, characterized in that, Both the first straightening module and the second straightening module include a first cylinder fixed on the horizontal support plate and a straightening fork plate that moves along the Y direction driven by the first cylinder; when the two straightening forks in the first straightening module and the second straightening module come close to each other, they are stacked together.

3. The lead wire straightening module as described in claim 2, characterized in that, The free end of the corrective fork is provided with a Y-direction extending lead wire limiting groove; one end of the lead wire limiting groove is an open structure.

4. The lead wire straightening module as described in claim 1, characterized in that, The first clamping module and the second clamping module respectively clamp the root of the two bent leads at the same location.

5. The lead wire straightening module as described in claim 1, characterized in that, Both the first pressing module and the second pressing module include a second cylinder fixed on the horizontal support plate and a pressing plate that is driven by the second cylinder to move in the X direction.

6. A small piece placement device, characterized in that, It includes: The visual positioning unit is used to visually locate the position of the leads on the photovoltaic module. A lead wire correction unit, guided by the visual positioning unit, corrects the position of the leads on the photovoltaic module, and includes a second support beam, a Z-axis drive module fixed on the second support beam, a third support beam driven by the Z-axis drive module to move up and down, and a lead wire correction module as described in any one of claims 1 to 5, which is movably arranged on the third support beam along the X direction. The small piece handling and placement unit picks up small pieces of material and places them at the photovoltaic module lead position; The small piece handling and placement unit and the visual positioning unit are located on both sides of the lead wire correction unit in the Y direction.

7. The small piece placement device as described in claim 6, characterized in that, The visual positioning unit includes a first support beam, a plurality of cameras spaced apart along the X direction on the first support beam, and a light source that illuminates a designated area on the photovoltaic module.

8. The small piece placement device as described in claim 6, characterized in that, The lead wire straightening unit includes a second support beam, a Z-axis drive module fixed on the second support beam, and a third support beam that is driven by the Z-axis drive module to move up and down. Multiple lead wire straightening modules are movably arranged on the third support beam along the X direction. A first rack extending along the X direction is provided on the third support beam. The first motor is fixed on the first support plate and a first drive gear that meshes with the first rack is provided on its movable end.

9. The small piece placement device as described in claim 6, characterized in that, The small piece handling and placement unit includes a YZ drive module, a fourth support beam disposed at the movable end of the YZ drive module, and multiple small piece adsorption modules disposed on the fourth support beam along the X direction. Each small piece adsorption module includes a second motor, a second support plate driven by the second motor to move along the X direction, a third cylinder fixed on the second support plate, and a suction nozzle module driven by the third cylinder to move up and down. A second rack extending along the X direction is disposed on the fourth support beam, and the second motor is fixed on the second support plate with a second drive gear meshing with the second rack at its movable end.

10. The small piece placement device as described in claim 6, characterized in that, It also includes a gantry support, and the visual positioning unit and the guide wire correction unit are adjustablely mounted on the gantry support along the Y direction.

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