Waste solar module feeding method and feeding equipment

Abstract

A method and equipment for feeding waste solar modules are disclosed. The method includes several feeding steps. Each feeding step includes a lifting sub-step and a conveying sub-step. In the lifting sub-step, a drive unit drives a lifting platform to raise a stack of waste solar modules until the topmost waste solar module in the stack is not lower than a working platform. In the conveying sub-step, the topmost waste solar module is conveyed to the working platform. This invention uses a drive unit to drive the lifting platform to raise the stack of waste solar modules, providing a more labor-saving or cost-effective solution compared to existing methods.

Description

[Technical Field]

[0001] This invention relates to a method and equipment for recycling green energy power generation equipment, and in particular to a method and equipment for feeding waste solar modules. [Previous Technology]

[0002] Green energy generation is one of China's important energy policies, and one important type of green energy generation is solar power generation. Solar power generation is implemented by laying out numerous solar modules (commonly known as solar panels). As the usage time increases, the power generation efficiency of solar modules will decrease, and newer models of solar modules will have better power generation efficiency than older models. Therefore, after a period of use, solar modules need to be replaced to maintain power generation efficiency at a level that meets usage requirements or economic benefits.

[0003] As mentioned earlier, since a considerable number of solar modules are required for solar power generation, improper recycling of these modules will impose a significant burden on the environment. A typical waste solar module includes an outer frame, a glass panel, a solar cell, and a backsheet, among other layers, housed within the frame. Because these layers are encapsulated by the outer frame, the frame must be removed before the individual layers can be recycled.

[0004] Currently, there are already frame removal machines capable of automatically removing the outer frame of waste solar modules. These frame removal machines typically have a work platform for placing a single waste solar module. During recycling operations, waste solar modules are usually stacked in groups on a pallet to facilitate the movement of these stacks by forklifts. After the stacks of waste solar modules are transported to the frame removal machine, they are lifted one by one onto the work platform by hand or a robotic arm, thereby feeding the waste solar modules into the frame removal machine.

[0005] Since each waste solar module typically weighs over 20 kg, manual handling is not only impossible to automate and is extremely time-consuming and labor-intensive, but also results in high long-term recycling costs due to labor costs. While using robotic arms can reduce long-term recycling costs, setting up robotic arms requires not only a high technical threshold but also a significant initial fixed investment. Therefore, it is necessary to provide a feeding method or equipment that differs from existing methods, offering the industry a third option besides the two methods mentioned above. [Summary of the Invention]

[0006] The purpose of the waste solar module feeding method of the present invention is to improve at least one of the disadvantages of the prior art.

[0007] The method for feeding waste solar modules according to the present invention includes several feeding steps. Each feeding step includes a lifting sub-step and a conveying sub-step. In the lifting sub-step, a driving unit drives a lifting platform to raise a stack of waste solar modules until the topmost waste solar module in the stack is not lower than a working platform. In the conveying sub-step, the topmost waste solar module is conveyed to the working platform.

[0008] The advantage of the waste solar module feeding method of the present invention is that the driving unit drives the lifting platform to rise and thus lift the waste solar module stack, eliminating the need to lift the waste solar modules with manpower or mechanical arms. Compared with the method of lifting the waste solar modules with manpower or mechanical arms, the waste solar module feeding method has the characteristics of saving labor or cost.

[0009] The purpose of the waste solar module feeding device of the present invention is to improve at least one of the disadvantages of the prior art.

[0010] The waste solar module feeding device of the present invention is suitable for conveying a pile of waste solar modules to a working platform. The waste solar module feeding device includes a lifting mechanism, at least one input side, and a feeding side.

[0011] The lifting mechanism includes a lifting platform suitable for carrying the waste solar module stack, and a drive unit capable of driving the lifting platform up or down. At least one input side is adapted for conveying the waste solar module stack onto the lifting platform. The feeding side faces the working platform and is adapted for conveying the waste solar modules placed on the lifting platform onto the working platform.

[0012] The advantage of the waste solar module feeding device of the present invention is that the driving unit drives the lifting platform to rise and thus lift the waste solar module pile. Compared with the method of lifting the waste solar modules by manpower or mechanical arms, the waste solar module feeding device has the characteristics of saving labor or cost.

Implementation Method

[0013] Referring to Figures 1, 2, and 3, in one embodiment of the waste solar module feeding method and feeding device of the present invention, a waste solar module feeding device 1 will be described first, and then a waste solar module feeding method M1 executed through the waste solar module feeding device 1 will be described.

[0014] The waste solar module feeding equipment 1 is suitable for feeding a number of waste solar modules 911 from a waste solar module stack 91 to a working platform 921 of a deframer 92.

[0015] Each of the waste solar modules 911 includes a glass panel 912, a back plate 913, a solar cell (not shown in the figure) located between the glass panel 912 and the back plate 913, and an outer frame 914 surrounding the glass panel 912 and the back plate 913. Each of the waste solar modules 911 includes a glass side 915 formed by the glass panel 912 and the outer frame 914, and a back plate side 916 formed by the back plate 913 and the outer frame 914.

[0016] In this embodiment, the waste solar module stack 91 is placed on a pallet 93 to facilitate the horizontal transport of the waste solar module stack 91 by a forklift (not shown) and the pallet 93.

[0017] Referring to Figures 2, 4, and 5, the waste solar module feeding equipment 1 includes a frame structure 2 erected next to the working platform 921 of the deframer 92, and a lifting mechanism 3, a height detection mechanism 4, a conveying mechanism 5, a facing detection mechanism 6, and a warning mechanism 7 installed on the frame structure 2.

[0018] The frame structure 2 includes four columns 21 that are spaced apart from each other and extend vertically, a frame 22 that is rectangular and integrally connected to the top of the columns 21, and two support plates 23 that extend vertically upward from the two long sides of the frame 22.

[0019] The support pillars 21 cooperate with the frame 22 to define three input sides 24 and one feeding side 25.

[0020] The input sides 24 correspond to one short side and two long sides of the frame 22, respectively. Each input side 24 is adapted to transport the waste solar module stack 91 placed on the pallet 93 to the lifting mechanism 3. The feeding side 25 is adapted to transport the waste solar modules 911 placed on the lifting mechanism 3 to the working platform 921 of the deframer 92. In this embodiment, one of the input sides 24 and the feeding side 25 are arranged back-to-back along a first direction D1. The remaining two input sides 24 are arranged left-to-right along a second direction D2. That is, the input sides 24 and the feeding side 25 cooperate around the lifting platform 32 in the back-to-back and left-to-right directions.

[0021] Referring to Figures 2, 4, and 6, the lifting mechanism 3 includes a drive unit 31 disposed on the support plates 23, and a lifting platform 32 located between the pillars 21 and capable of being driven by the drive unit 31 to rise or fall.

[0022] The drive unit 31 includes four transmission sprockets 311 spaced apart from each other, two first synchronous shafts 312 that insert the transmission sprockets 311 onto the support plates 23, two synchronous sprockets 313 respectively fitted onto the first synchronous shafts 312, a synchronous chain 314 that is respectively engaged with the synchronous sprockets 313, four transmission chains 315 that are respectively engaged with the transmission sprockets 311 and connected to the lifting platform 32, a first drive source (not shown) that can drive one of the first synchronous shafts 312 to rotate, and four counterweights 316 respectively connected to the transmission chains 315.

[0023] The transmission sprockets 311 are arranged in pairs. The transmission sprockets 311 in the same group are opposite each other on the left and right sides and are located inside the support plates 23 respectively. The transmission sprockets 311 located on the same side on the left and right sides are spaced apart from each other.

[0024] Each of the first synchronous pulley shafts 312 is inserted into the same set of left and right opposite transmission sprockets 311 so that the left and right opposite transmission sprockets 311 rotate synchronously.

[0025] The synchronization chains 314 are used to make the synchronization sprockets 313 and the first synchronization wheel shafts 312 rotate synchronously.

[0026] One end of each of the transmission chains 315 is connected to the lifting platform 32. The other end of each of the transmission chains 315 is connected to the respective counterweight 316.

[0027] The first drive source may, for example, be a motor that provides power for the operation of the drive unit 31. When the drive unit 31 is in operation, the lifting platform 32 can be raised or lowered via the transmission chains 315 under the drive of the first drive source.

[0028] Each counterweight 316 can prevent the other drive chain 315 from shaking when the lifting platform 32 is raised or lowered.

[0029] Referring to Figures 2, 3, and 4, the height detection mechanism 4 is disposed on one of the two long sides of the frame 22, and the bottom end of the height detection mechanism 4 is higher than the top surface of the working platform 921. Preferably, the height H1 of the bottom end of the height detection mechanism 4 above the top surface of the working platform 921 is less than the thickness T1 of the outer frame 914 of the waste solar module 911. Specifically, the thickness T1 of the outer frame 914 of the waste solar module 911 is approximately 30-47 mm, so the distance between the bottom end of the height detection mechanism 4 and the top surface of the working platform 921 only needs to be less than 30 mm, for example, 1, 5, 10, 15, 20, 25, or 29 mm. In other embodiments of the present invention, the bottom end of the height detection mechanism 4 and the top surface of the working platform 921 may also be at the same height. The height detection mechanism 4 can emit light horizontally and detect whether there is an object (in this embodiment, a waste solar module 911) with a height equal to or similar to that of the height detection mechanism 4 by reflecting the light.

[0030] Referring to Figures 2, 4, and 6, the conveying mechanism 5 can convey one of the waste solar modules 911 to the working platform 921, and includes a push rod 51 for pushing the waste solar module 911 forward, and a moving unit 52 that can drive the push rod 51 to move laterally.

[0031] The moving unit 52 includes eight drive wheels 521, a second synchronous pulley shaft 522 inserted into two of the left and right opposite pulleys, two drive belts 523 spaced apart from each other and stretched on the drive wheels 521, two support seats 524 respectively clamped on the drive belts 523, two bearing assemblies 525 respectively disposed on the support seats 524, and two guide rods 526 respectively inserted into the bearing assemblies 525.

[0032] When the transmission wheels 521 rotate, they can drive the transmission belts 523 to move, thereby driving the push rod 51 to move back and forth via the support seats 524. The second synchronous pulley shafts 522 can be driven to rotate by a second drive source (not shown), thereby driving the transmission wheels 521 to rotate. Each bearing assembly 525 is fitted onto a separate guide rod 526 for stable back and forth movement of the separate support seats 524. Each guide rod 526 is U-shaped, with its middle portion extending parallel to a separate support plate 23. The two opposite ends of each guide rod 526 extend toward the separate support plate 23 to connect to the separate support plate 23. Each guide rod 526 may be threaded and assembled with the separate support plate 23 via elements such as nuts and washers.

[0033] Referring to Figures 2, 3, and 7, the height of the facing detection mechanism 6 is higher than that of the working platform 921, and the facing detection mechanism 6 is a laser rangefinder that can project light downwards, capable of measuring the distance between the facing detection mechanism 6 and the waste solar module 911 located below the facing detection mechanism 6. Since each waste solar module 911 includes a glass side 915 and a back plate side 916, as shown in Figures 3 and 7, the change in distance measured by the facing detection mechanism 6 can be used to determine whether the uppermost waste solar module 911 in the waste solar module pile 91 is facing upwards with its glass side 915 or its back plate side 916.

[0034] For example, suppose one of the discarded solar modules 911 passes through the orientation detection mechanism 6 with its glass side 915 facing down and its back panel side 916 facing up. When one side of the outer frame 914, the back panel 913, and the other side of the outer frame 914 successively pass through the orientation detection mechanism 6, the distance detected by the orientation detection mechanism 6 will change as shown in Figure 3: short (one short side of the outer frame 914) - long (back panel 913) - short (the other short side of the outer frame 914). As another example, suppose the discarded solar module 911 passes through the orientation detection mechanism 6 with its glass side 915 facing up and its back panel side 916 facing down. Since the glass panel 912 is flush with the outer frame 914, the orientation detection mechanism 6 will not detect any change in height in the discarded solar module 911. Since the waste solar module 911 may be tilted and may be slightly deformed due to being discarded, Figures 3 and 7 only illustrate the ideal state. However, since the structure of the glass side 915 and the back panel side 916 of the waste solar module 911 is still different, it is still possible to determine whether the waste solar module 911 is facing upwards with the glass side 915 or the back panel side 916 by measuring the different distances caused by the height difference between the outer frame 914 and the glass panel 912 or the back panel 913.

[0035] Referring to Figure 1, the warning mechanism 7 is a display with a speaker and a screen.

[0036] Referring to Figures 1, 5, and 8, the feeding method M1 for the waste solar modules includes an input step S1, several repeatedly executed feeding steps S2, and a termination step S3.

[0037] In the input step S1, the pallet 93 is supported by a stack of lifting machines to place the pallet 93, along with the waste solar module stack 91, onto the lifting platform 32 of the lifting mechanism 3. During placement, the waste solar module stack 91 is placed onto the lifting platform 32 through one of the input sides 24, which are positioned differently from each other. For example, it can be placed onto the lifting platform 32 from back to front along the first direction D1 through one of the input sides 24. Alternatively, it can be placed onto the lifting platform 32 from left or right along the second direction D2 through the other two input sides 24.

[0038] Each feeding step S2 includes a lifting sub-step S21, a conveying sub-step S22, a first judgment sub-step S23, a warning sub-step S24, and a second judgment sub-step S25.

[0039] Referring to Figures 1, 8, and 9, in each lifting sub-step S21, the lifting platform 32 is raised by the drive unit 31 of the lifting mechanism 3 to lift the waste solar module stack 91 and the pallet 93. Specifically, the waste solar module stack 91 and the pallet 93 are raised until the uppermost waste solar module 911 is at the same height as the height detection mechanism 4 and can be detected by the height detection mechanism 4, at which point the lifting stops.

[0040] Referring to Figures 1, 9, and 10, in each of the conveying sub-steps S22, the push rod 51 of the conveying mechanism 5 pushes the uppermost waste solar module 911 toward the working platform 921, so that the waste solar module 911, with one end tilted down and the other end tilted up, first contacts the top surface of the working platform 921, and then continues to be pushed by the push rod 51 to move completely onto the working platform 921.

[0041] During the execution of the conveying sub-step S22, that is, during the process of the waste solar module 911 being pushed and passing under the facing detection mechanism 6, the facing detection mechanism 6 will continuously measure the distance between the facing detection mechanism 6 and the waste solar module 911 passing below, and transmit the measurement result to a control unit 8 that is signal-connected to the facing detection mechanism 6.

[0042] In the first judgment sub-step S23, the measurement result is used to determine whether the pushed waste solar module 911 is facing upward with the glass side 915 or the back panel side 916.

[0043] In this embodiment, since the frame removal machine 92 requires the waste solar module 911 to operate with the back panel side 916 facing up and the glass side 915 facing down, if the control unit 8 determines that the waste solar module 911 is pushed into the frame removal machine 92 with the glass side 915 facing up and the back panel side 916 facing down, then the warning sub-step S24 will be executed.

[0044] In the warning sub-step S24, the control unit 8 can signal control the warning mechanism 7 to emit a warning sound through the speaker or display a warning message on the screen to remind the staff to turn over the waste solar module 911 that will be pushed to the deframe machine 92.

[0045] If the control unit 8 determines that the waste solar module 911 is correctly pushed into the deframe machine 92 with the back panel side 916 facing up and the glass side 915 facing down, then the second determination sub-step S25 is executed.

[0046] Referring to Figures 1, 10, and 11, in the second judgment sub-step S25, it is determined whether the lifting platform 32 has reached a preset height. If the lifting platform 32 has not yet reached the preset height, the feeding step S2 is executed again, specifically, the lifting sub-step S21 of the feeding step S2 is executed. If the lifting platform 32 has reached the preset height, it means that, as shown in Figure 11, all (or almost) of the waste solar modules 911 in the waste solar module stack 91 have been sent to the deframer 92, and therefore the termination step S3 will be executed.

[0047] In the termination step S3, the warning mechanism 7 can issue a different prompt sound or message than the flipping to notify the staff to replenish another pile of the waste solar module pile 91.

[0048] One of the features of the present invention is that the lifting platform 32 is driven by the driving unit 31 to lift the waste solar module stack 91. Since no human power or robotic arm is required, the present invention is labor-saving or cost-saving compared to the existing methods.

[0049] A second feature of the present invention is that the input sides 24, located in different positions, allow workers to input the pallet 93 and the waste solar module stack 91 from different directions. In other words, the waste solar module feeding device 1 is less likely to be unusable due to obstruction on one side. Alternatively, it can be said that because the waste solar module feeding device 1 can feed from multiple directions, it can be installed in many locations, making the factory configuration more flexible.

[0050] A third feature of the present invention is that the orientation detection mechanism 6 can be used by the control unit 8 to determine whether the waste solar module 911 located at the top is facing upward with the glass side 915 or the back panel side 916, thereby facilitating the correct execution of the subsequent frame removal operation by the frame removal machine 92.

[0051] The fourth feature of the present invention is that the height detection mechanism 4 can help determine whether the waste solar module 911 has risen to an appropriate height, so that the feeding step S2 can be repeatedly executed.

[0052] The fifth feature of the present invention is that: through the first synchronous wheel shafts 312, the synchronous sprockets 313 and the synchronous chain 314, the transmission sprockets 311 can rotate synchronously, so that only one of the first drive sources is needed to drive the transmission sprockets 311 to rotate simultaneously, so that the four corners of the lifting platform 32 rise or fall synchronously.

[0053] In other embodiments of the present invention, the first determination sub-step S23 may also be performed before the conveying sub-step S22. For example, if the orientation detection mechanism 6 is mounted on a drive device that can move back and forth, and the drive device can be mounted on the frame structure 2, then the orientation detection mechanism 6 can be moved relative to the waste solar module 911 by the drive device before pushing the uppermost waste solar module 911, so as to determine whether the uppermost waste solar module 911 faces upward with the glass side 915 or the back plate side 916.

[0054] In summary, the advantages of the waste solar module feeding method and feeding equipment of the present invention are: the driving unit 31 drives the lifting platform 32 to rise and thus lift the waste solar module stack 91, without the need for manual or mechanical arms to lift the waste solar modules 911, providing a solution different from the existing methods.

[0055] The above description is merely an embodiment of the present invention and should not be construed as limiting the scope of the patent application of the present invention. Any simple equivalent changes and modifications made in accordance with the scope of the patent application and the patent specification of the present invention should also be covered by the scope of the patent application of the present invention. [Simplified Explanation of the Diagram]

[0056] Other features and effects of the present invention will be clearly presented in the embodiments with reference to the drawings, wherein: Figure 1 is a flowchart illustrating a method for feeding a waste solar module according to an embodiment of the present invention; Figure 2 is a perspective view illustrating a waste solar module feeding device and a waste solar module stack and a pallet used in conjunction with the embodiment; Figure 3 is an incomplete and partially sectional view illustrating the relative relationship between a face detection mechanism and a waste solar module in the waste solar module stack, with the waste solar module having its back plate side facing upward and its glass side facing downward; Figure 4 is an incomplete and partially sectional view illustrating the waste solar module feeding device; Figure 5 is a top view illustrating the feeding method of the waste solar module stack; Figure 6 is a top view illustrating a lifting mechanism and a conveying mechanism according to the embodiment; Figure 7 is an incomplete and partially sectional view illustrating the relative relationship between the face detection mechanism and the waste solar module, with the waste solar module having its glass side facing upward and its back plate side facing downward; Figure 8 is an incomplete and partially sectional view illustrating one of the operating processes of the waste solar module feeding equipment; Figure 9 is an incomplete and partially sectional view illustrating one of the operating processes of the waste solar module feeding equipment; Figure 10 is an incomplete and partially sectional view illustrating one of the operating processes of the waste solar module feeding equipment; and Figure 11 is an incomplete and partially sectional view illustrating one of the operating processes of the waste solar module feeding equipment.

Claims

1. A method for feeding waste solar modules, comprising: several feeding steps, each feeding step including a lifting sub-step and a conveying sub-step, wherein in the lifting sub-step, a driving unit drives a lifting platform to raise a pile of waste solar modules until the topmost waste solar module in the pile is not lower than a working platform, and in the conveying sub-step, the topmost waste solar module is pushed to the working platform by a push rod.

2. The method for feeding waste solar modules as described in claim 1, wherein, In each of these lifting sub-steps, the stack of waste solar modules is raised until the bottom of the uppermost waste solar module is higher than the top surface of the work platform.

3. The method for feeding waste solar modules as described in claim 1, wherein, Each feeding step also includes a first judgment sub-step, in which it is determined whether the waste solar module at the top of the waste solar module stack is facing upward with its glass side or its back plate side facing upward.

4. The method for feeding waste solar modules as described in claim 3, wherein, In each of the first judgment sub-steps, the distance between the detection mechanism and different parts of the waste solar module at the top of the waste solar module pile is measured by a detection mechanism to determine whether the waste solar module at the top is facing upwards with the glass side or the back plate side.

5. The method for feeding waste solar modules as described in claim 1 further includes an input step prior to the feeding steps, in which the waste solar modules are stacked onto the lifting platform via one of three input sides located at different positions.

6. A waste solar module feeding device, suitable for conveying a pile of waste solar modules to a working platform, the waste solar module feeding device comprising: a frame structure; a lifting mechanism disposed on the frame structure and including a lifting platform suitable for carrying the pile of waste solar modules, and a drive unit capable of driving the lifting platform to rise or fall; at least one input side suitable for conveying the pile of waste solar modules to the lifting platform; One feeding side faces the working platform and is adapted to push the waste solar modules placed on the lifting platform to the working platform; A conveying mechanism is provided on the frame structure and includes a push rod that can push the waste solar modules to the working platform, and a moving unit that can drive the push rod to move laterally.

7. The waste solar module feeding device as described in claim 6, comprising a plurality of the aforementioned input sides, the input sides cooperating with the feeding side around the lifting platform.

8. The feeding device for waste solar modules as described in claim 6, wherein each waste solar module includes a glass side and a back panel side opposite to each other, wherein, The waste solar module feeding equipment also includes a frame structure for the lifting mechanism, and a facing detection mechanism installed on the frame structure. The facing detection mechanism can measure the distance between the facing detection mechanism and different parts of the waste solar module at the top of the waste solar module pile to determine whether the waste solar module at the top is facing upwards with the glass side or the back plate side.

9. The waste solar module feeding device as described in claim 6 further includes a frame structure and a height detection mechanism disposed on the frame structure, the height detection mechanism being capable of detecting whether any of the waste solar modules is at the same height as the height detection mechanism.

10. The feeding device for waste solar modules as described in claim 6, wherein, The drive unit includes several transmission chains that connect to the lifting platform and can drive the lifting platform to rise or fall.

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