Visual monitoring system and method for glue dispensing ratio of glue components a and b

Abstract

A visual monitoring system and method for a glue dispensing ratio of glue components A and B. At least one liquid flow measurement device is mounted on each of glue pipelines where glue components A and B are dispensed, each liquid flow measurement device is connected to a control device, and the control device is connected to an alarm device; the qualified range of revolutions of an impeller of each of a glue component A dispensing pipe and a glue component B dispensing pipe and the qualified range of the ratio of revolutions of the impeller of each of the glue component A dispensing pipe and the glue component B dispensing pipe are preset separately; glue passes through the impellers on the glue component A dispensing pipe and the glue component B dispensing pipe and drives the impellers to rotate, and revolution data of a second gear is acquired in real time by means of a revolution processing module; and the control device compares the revolution data of each impeller with the corresponding preset qualified range of the revolutions of the impeller in real time, and determines whether the liquid flow is abnormal on the basis of a comparison result, and the alarm device gives an alarm if the liquid flow is abnormal. According to the present application, the glue dispensing amount and the glue dispensing ratio of the glue components A and B can be monitored in real time.

Description

A visual monitoring system and method for the glue output ratio of components A and B

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to the Chinese patent application filed with the China Patent Office on November 21, 2023, with application number 202311553136.0 and invention name “A visual system and method for monitoring the glue output ratio of components A and B”, the entire contents of which are incorporated by reference into this application. Technical Field

[0003] The present application relates to the technical field of photovoltaic module manufacturing, and in particular to a visual monitoring system and method for the glue discharge ratio of components A and B. Background Art

[0004] In the photovoltaic module industry, junction boxes rely on potting compound to protect the electronic components within, providing thermal conductivity, insulation, flame retardancy, and waterproofing. Currently, potting compound is divided into two types: component A and component B. After mixing components A and B in appropriate proportions, they cure under suitable temperature and humidity conditions. Component B is the key to curing. Excessive or insufficient component B—that is, an unsuitable ratio of components A to B—can lead to curing anomalies after mixing, impacting the reliability of the photovoltaic module.

[0005] There are two existing quality inspection methods in the industry. The first is the weighing measurement method: every 4 hours, weigh the A and B component glues discharged once respectively to determine whether their ratio is qualified. The second is the sample observation method. After mixing the A and B component glues discharged once, wait for 15 to 20 minutes to observe their surface drying conditions, and wait for 2 hours to observe their curing conditions. Based on the above two observation conclusions, determine whether the ratio of the A and B component glues discharged once is qualified. Both methods require personnel to perform additional sampling operations. The sampling and conclusion judgment process is cumbersome, which affects production efficiency. In addition, when using the second method for judgment, it is found that the problem cycle is long. While waiting for the results, the production line continues to produce. Therefore, the lag of this detection method is too strong, and abnormalities cannot be controlled in time. There is a hidden danger of reliability abnormalities in large quantities of components.

[0006] Summary of the Invention

[0007] To this end, the present application provides a visual monitoring system and method for the glue output ratio of components A and B, which can monitor the glue output amount and glue output ratio of components A and B in real time, and realize timely detection and resolution of abnormal conditions.

[0008] To solve the above technical problems, the present application provides a liquid flow detection device, comprising:

[0009] A cavity-type container shell having a hose connection port;

[0010] An impeller is disposed in the cavity container housing and is located beside the hose connection port, and is capable of rotating under the propulsion of the liquid;

[0011] The housing of the rotation number amplifying device is connected to the housing of the cavity container, and the housing of the rotation number amplifying device is provided with:

[0012] A main shaft, one end of which is connected to the center of the impeller and rotates around itself as the impeller rotates;

[0013] a first gear, the center of which is connected to the other end of the main shaft, the first gear having the same rotation speed as the impeller and provided with internal teeth;

[0014] a second gear having external teeth meshing with the internal teeth of the first gear;

[0015] a laser emitting module disposed beside the second gear, the laser emitting module comprising a laser emitting end and a laser receiving end, wherein the teeth of the second gear are capable of intermittently blocking the laser emitted from the laser emitting end to the laser receiving end when the second gear rotates;

[0016] A revolution processing module and a signal transmitting module connected thereto, wherein the revolution processing module is used to obtain the tooth signal and transmit it to the control module through the signal transmitting module for processing to obtain the revolution of the second gear, and the revolution of the first gear and the impeller is obtained based on the revolution of the second gear.

[0017] In one embodiment of the present application, the first gear has the same rotation speed as the impeller.

[0018] In one embodiment of the present application, the cavity-type container shell is a transparent structure.

[0019] In one embodiment of the present application, the liquid flow detection device is included.

[0020] The present application also provides a visual monitoring system for the glue output ratio of components A and B, wherein the liquid flow detection devices are respectively installed on the glue output hose lines of components A and B, and each of the liquid flow detection devices is connected to a control device, and the control device is connected to an alarm device.

[0021] The present application also provides a visual method for monitoring the glue discharge ratio of components A and B. At least one liquid flow detection device is installed on the glue discharge hose line of component A and component B, respectively. Each of the liquid flow detection devices is connected to a control device, and the control device is connected to an alarm device.

[0022] According to the qualified glue output range of group A and group B, the qualified impeller speed range of group A and group B glue output pipes and the qualified impeller speed ratio range of group A and group B glue output pipes are preset respectively;

[0023] The glue passes through the impellers on the glue outlet pipes of group A and group B and drives the impellers to rotate. The speed processing module obtains the speed data of the second gear in real time, and obtains the speed data of the impeller based on the speed data of the second gear.

[0024] The control device compares the impeller rotation data with the corresponding preset qualified impeller rotation range in real time, and determines whether there is an abnormality in the liquid flow based on the comparison result. If there is an abnormality, the alarm device will sound an alarm.

[0025] In one embodiment of the present application, the determining whether the liquid flow rate is abnormal, and if so, the alarm device issuing an alarm, includes:

[0026] When the impeller revolutions on the rubber outlet pipe of group A, the impeller revolutions on the rubber outlet pipe of group B, and the ratio of the impeller revolutions on the rubber outlet pipes of group A to group B are all 0, it is a standby state and the alarm device does not sound an alarm;

[0027] When the speed of the impeller on the rubber outlet pipe of group A or the speed of the impeller on the rubber outlet pipe of group B is 0, the surface rubber pipe is blocked and the alarm device sends out a first-level alarm;

[0028] When either the impeller speed on the glue outlet pipe of group A or the impeller speed on the glue outlet pipe of group B is outside the qualified impeller speed range, or when the impeller speed ratio of the impellers on the glue outlet pipes of group A and group B is outside the qualified speed ratio range, the alarm device issues a second-level alarm.

[0029] In one embodiment of the present application, the first level alarm intensity is greater than the second level alarm intensity.

[0030] In one embodiment of the present application, a digital display device connected to the control device is further included, and the digital display device is used to display the number of revolutions of the impeller in the respective liquid flow detection devices on the group A rubber outlet pipe and the group B rubber outlet pipe in real time.

[0031] In one embodiment of the present application, the control device adopts PLC.

[0032] In one embodiment of the present application, the glue passes through the impellers on the glue outlet pipes of group A and the glue outlet pipes of group B and drives the impellers to rotate, including:

[0033] The glue filling port is opened and glue begins to flow out, and the impeller is pushed by the glue and starts to rotate;

[0034] The glue filling port is closed and the glue discharging is completed. One glue discharging process lasts for 3 seconds. The number of revolutions of the impeller is obtained only during the discharging time.

[0035] The above technical solution of the present application has the following advantages over the prior art:

[0036] The present application discloses a visual monitoring system and method for the discharge ratio of components A and B. By installing at least one cavity container with a built-in impeller on the discharge hose lines of components A and B, the impeller inside can be observed through the outer wall of the container. The system observes whether the impeller is rotated by the discharge action, thereby visualizing the discharge of components A and B.

[0037] In this application, the impeller speed value directly reflects the glue output of each component glue and the glue output ratio of components A and B, realizing the visualization of the glue output ratio of components A and B.

[0038] In this application, the impeller is linked with the speed processing module and the alarm device. By recording the impeller speed of each component A and B glue, it is determined whether the glue output ratio of component A and component B is within the qualified range. If the glue output ratio is abnormal, the alarm device will immediately sound an alarm to remind personnel to come to investigate and deal with the abnormality.

[0039] In this application, production personnel can quickly identify the abnormal glue category and determine the abnormal type (hose blockage, excessive glue output or insufficient glue output) based on the speed of the A and B component glue impellers, so as to quickly respond to different abnormal situations, save time for abnormal handling, and reduce scrapping and saving costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] In order to make the contents of this application easier to understand, the application is further described in detail below based on the specific embodiments of this application and in conjunction with the accompanying drawings.

[0041] FIG1 is a schematic diagram of a visual monitoring system for the glue output ratio of components A and B of the present application.

[0042] FIG2 is a flow chart of the overall method for monitoring the glue output ratio of components A and B in this application.

[0043] FIG3 is a flow chart of a method for monitoring the glue output ratio of components A and B using a PLC control visualization method of the present application.

[0044] FIG4 is a schematic cross-sectional view of the structure of the liquid flow detection device of the present application.

[0045] FIG5 is a schematic diagram of the gear meshing structure in the liquid flow detection device of the present application.

[0046] FIG6 is a schematic diagram showing the arrangement of the laser emission module and the revolution processing module in the liquid flow detection device of the present application.

[0047] Description of the accompanying drawings:

[0048] 1. Cavity container shell; 11. Hose connection port;

[0049] 2. Impeller;

[0050] 3. Housing of the revolution amplifying device;

[0051] 4. Main shaft;

[0052] 5. First gear;

[0053] 6. Second gear;

[0054] 7. Laser emission module;

[0055] 8. Revolution processing module. DETAILED DESCRIPTION

[0056] The present application will be further described below in conjunction with the accompanying drawings and specific embodiments so that those skilled in the art can better understand the present application and implement it, but the embodiments are not intended to limit the present application.

[0057] In this application, if there is a description of directions (up, down, left, right, front and back), it is only for the convenience of describing the technical solution of this application, and does not indicate or imply that the technical features referred to must have a specific orientation, be constructed and operate in a specific orientation. Therefore, it cannot be understood as a limitation on this application.

[0058] In this application, "several" means one or more, "multiple" means more than two, "greater than," "less than," and "exceed" are understood to exclude the number itself; "above," "below," and "within" are understood to include the number itself. In the description of this application, the use of "first" or "second" is solely for the purpose of distinguishing technical features and is not to be construed as indicating or implying relative importance, implicitly specifying the number of the indicated technical features, or implicitly specifying the order of the indicated technical features.

[0059] In this application, unless otherwise expressly defined, terms such as "disposed," "installed," and "connected" should be interpreted broadly. For example, they may refer to direct connection or indirect connection through an intermediate medium; fixed connection or detachable connection or integral molding; mechanical connection or electrical connection or mutual communication; and internal connection between two components or interaction between two components. Persons skilled in the art can reasonably determine the specific meanings of these terms in this application based on the specific content of the technical solution.

[0060] 2 and 3 , a visual method for monitoring the glue output ratio of components A and B includes the following steps:

[0061] S1. Install at least one liquid flow detection device on the glue discharge hose lines of group A and group B, respectively. Each liquid flow detection device is connected to a control device, and the control device is connected to an alarm device;

[0062] S2. Preset the qualified impeller 2 speed ranges of the glue outlet pipes of group A and group B and the qualified impeller 2 speed ratio ranges of the impellers 2 of the glue outlet pipes of group A and group B respectively based on the qualified glue output ranges of the glue outlet pipes of group A and group B; the glue passes through the impellers 2 of the glue outlet pipes of group A and group B and drives the impellers 2 to rotate, and the speed processing module 8 obtains the speed data of the second gear 6 in real time, and obtains the speed data of the impeller 2 based on the speed data of the second gear 6;

[0063] S3, the control device compares the rotation speed data of the impeller 2 with the corresponding preset qualified impeller 2 rotation speed range in real time, and determines whether there is an abnormality in the liquid flow based on the comparison result. If there is an abnormality, the alarm device issues an alarm;

[0064] S4. Production personnel come to handle the abnormality according to the alarm, determine which hose has the abnormality based on the rotational speed, and complete the treatment quickly.

[0065] The above method utilizes a visual monitoring system for the glue output ratio of components A and B. As shown in Figure 1, the liquid flow detection devices are respectively installed on the glue output hose lines of components A and B. Each of the liquid flow detection devices is connected to a control device, and the control device is connected to an alarm device. The control device can adopt a PLC controller, and the alarm device adopts an audible and visual alarm, a buzzer, etc.

[0066] 4 to 6 , in this embodiment, the liquid flow detection device includes:

[0067] The cavity-type container housing 1 has a hose connection port 11 connected to the rubber outlet hoses of group A and group B;

[0068] The impeller 2 is disposed in the cavity container housing 1 and is located beside the hose connection port 11 and is capable of rotating under the propulsion of the liquid;

[0069] The rotation number amplifying device housing 3 is connected to the cavity container housing 1, and the rotation number amplifying device housing 3 is provided with:

[0070] The main shaft 4 has one end connected to the center of the impeller 2 and rotates around itself when the impeller 2 rotates;

[0071] A first gear 5, the center of which is connected to the other end of the main shaft 4, the first gear 5 has the same rotation speed as the impeller 2 and is provided with internal teeth;

[0072] a second gear 6 provided with external teeth meshing with the internal teeth of the first gear 5;

[0073] a laser emitting module 7 disposed beside the second gear 6, comprising a laser emitting end and a laser receiving end. When the second gear 6 rotates, the teeth of the laser emitting module 7 can intermittently block the laser emitted from the laser emitting end to the laser receiving end, thereby forming a tooth signal;

[0074] The speed processing module 8 and the signal transmitting module connected thereto (which may also be built into the speed processing module 8) are used to obtain the tooth signal and transmit it to the control module through the signal transmitting module for processing to obtain the speed of the second gear 6. According to the speed of the second gear 6, the speed of the first gear 5 and the impeller 2 can be obtained.

[0075] Among them, the first gear 5 has the same number of revolutions as the impeller 2; the cavity-type container shell 1 is sealed at the top and bottom (in order to show the internal structure, its upper surface is not shown in the figure); the installation method on the glue discharge hose line can be selected to be directly connected in series in the hose line, and a flange connection can be used to connect the upper section of the hose to the hose close to the discharge barrel side, and connect the lower section of the hose to the hose close to the glue filling port side.

[0076] The gear ratio of the second gear 6 to the first gear 5 is 1:4, that is, the first gear 5 rotates 1 circle, which drives the second gear 6 to rotate 4 circles, achieving the effect of amplifying the number of revolutions; the laser emitting module 7 is a laser emitter that emits laser at one end and receives laser at the other end. As the second gear 6 rotates, the teeth will block the laser path, resulting in the inability to receive laser. The laser module transmits information such as laser and no laser to the number of revolutions processing module 8; the number of revolutions processing module 8 receives the signal transmitted by the laser module, integrates one with laser and one without laser into a set of tooth signals, and is provided with a signal transmitting module to transmit the tooth signal to the control device. The control device processes the operation and divides the sum of the tooth signals by the number of teeth of the second gear 6 to obtain the number of revolutions of the second gear 6; the number of revolutions processing module 8 can adopt a microcontroller (MCU), and the signal transmitting module is a 4G signal transmitting module or a 5G signal transmitting module.

[0077] In some embodiments, the cavity container shell 1 is a transparent structure, and the internal impeller 2 can be observed through the outer wall of the container; it is observed whether the impeller 2 is driven to rotate by the glue discharge action to achieve visualization of the glue discharge of components A and B.

[0078] In one embodiment of the present application, the determining whether the liquid flow rate is abnormal, and if so, the alarm device issuing an alarm, includes:

[0079] When the impeller 2 revolutions on the rubber outlet pipe of group A, the impeller 2 revolutions on the rubber outlet pipe of group B, and the ratio of the impeller 2 revolutions on the rubber outlet pipes of group A and group B are all 0, it is in standby state and the alarm device does not sound an alarm;

[0080] When the speed of impeller 2 on the rubber outlet pipe of group A or the speed of impeller 2 on the rubber outlet pipe of group B is 0, the rubber pipe is blocked and the alarm device sends out a first-level alarm;

[0081] When either the speed of the impeller 2 on the glue outlet pipe of group A or the speed of the impeller 2 on the glue outlet pipe of group B is outside the qualified impeller 2 speed range, or the speed ratio of the impeller 2 on the glue outlet pipes of group A and group B is outside the qualified speed ratio range, the alarm device issues a second-level alarm.

[0082] In one embodiment of the present application, the first-level alarm intensity is greater than the second-level alarm intensity, and the alarm signals such as the light intensity and volume of the alarm light are different according to the abnormality level.

[0083] In this embodiment, a digital display device connected to the control device is also included. The digital display device is used to display in real time the number of revolutions of the impeller 2 in the liquid flow detection device on each of the group A glue outlet pipe and the group B glue outlet pipe. The number of revolutions of the second gear 6 can also be displayed on the digital display device, so that the speed value of the impeller 2 intuitively reflects the glue output of each component glue and the glue output ratio of the A and B components glue, thereby realizing the visualization of the glue output ratio of the A and B components glue.

[0084] In this embodiment, in the control device, the upper and lower limit values ​​of the impeller 2 rotation speed are inputted correspondingly according to the type of glue.

[0085] The glue filling port is opened, glue starts to flow out, and the impeller 2 is pushed by the glue and starts to rotate.

[0086] The glue filling port is closed and the glue discharge is completed. One glue discharge process lasts for 3 seconds. The number of revolutions of impeller 2 is calculated only during the discharge time.

[0087] After the discharge is completed, the number of revolutions of the impeller 2 during the discharge time will be transmitted to the control module. If the number of revolutions exceeds the set qualified range, an alarm will be triggered.

[0088] The production staff comes to handle the abnormality and judges the abnormal range according to the value on the digital display device. After the abnormality is handled, the alarm device is reset and the next glue filling operation is continued.

[0089] Specifically, in the case of one-time glue discharge, the glue discharge volume of group A is 10.6-17.5cm 3 , the glue volume of component B is 1.3-2.3cm 3 , the inner diameter of the rubber hose is 6mm, the diameter of the blade is 4mm, and the gear ratio of the first gear 5 to the second gear 6 is 4:1.

[0090] The qualified revolution range of component A glue is: 50.011-0.018 revolutions of the first gear and 60.045-0.074 revolutions of the second gear;

[0091] The qualified revolution range of component B glue is: 50.001-0.002 revolutions of the first gear and 60.006-0.010 revolutions of the second gear;

[0092] The ratio of qualified glue revolutions of group A and group B is: 4.52-12.98:1;

[0093] Since the number of revolutions per glue discharge is still small even after being amplified by 4 times, further amplification can be considered, or the number of revolutions can be monitored once for a total of 10 or 20 glue discharges; if the number of revolutions or the ratio of the number of revolutions is not within the qualified range, the control device triggers the alarm device to alarm.

[0094] Through the above method, production personnel can quickly identify the abnormal glue category and determine the abnormal type (hose blockage, excessive glue output or insufficient glue output) according to the rotation speed of the A and B component glue impellers, so as to quickly respond to different abnormal situations, save time for abnormal handling, and reduce scrap and save costs.

[0095] Finally, it should be noted that the above specific implementation methods are only used to illustrate the technical solutions of the present application and are not limiting. Although the present application is described in detail with reference to examples, ordinary technicians in this field should understand that the technical solutions of the present application can be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present application, which should be included in the scope of the claims of the present application.

Claims

1. A liquid flow detection device, characterized in that: include: The cavity-type container shell has a hose connection port; An impeller is disposed in the cavity container shell and is located beside the hose connection port, and can rotate under the impetus of the liquid; The shell of the rotation number amplifying device is connected to the shell of the cavity container, and the shell of the rotation number amplifying device is provided with: A main shaft, one end of which is connected to the center of the impeller and rotates around itself as the impeller rotates; A first gear, the center of which is connected to the other end of the main shaft, the first gear having the same rotation speed as the impeller and provided with internal teeth; a second gear having external teeth meshing with the internal teeth of the first gear; A laser emitting module is arranged beside the second gear, the laser emitting module comprises a laser emitting end and a laser receiving end, and the teeth of the second gear can intermittently block the laser emitted from the laser emitting end to the laser receiving end when the second gear rotates; A speed processing module and a signal transmitting module connected thereto, wherein the speed processing module is used to obtain a tooth signal and transmit the signal to the control module for processing via the signal transmitting module to obtain the speed of the second gear, and the speed of the first gear and the impeller is obtained based on the speed of the second gear.

2. The liquid flow detection device according to claim 1, characterized in that: The first gear has the same number of rotations as that of the impeller.

3. The liquid flow detection device according to claim 1, characterized in that: The cavity-type container shell is a transparent structure.

4. A visual monitoring system for the glue output ratio of components A and B, characterized in that: It comprises the liquid flow detection device as described in any one of claims 1-3, and the liquid flow detection device is respectively installed on the hose lines of group A and group B glue outlet, each of the liquid flow detection devices is connected to a control device, and the control device is connected to an alarm device.

5. A visual method for monitoring the glue output ratio of component A and component B, characterized in that: include: At least one liquid flow detection device according to any one of claims 1 to 3 is installed on the rubber hose lines for discharging the glue of group A and group B, respectively, and each of the liquid flow detection devices is connected to a control device, and the control device is connected to an alarm device; According to the qualified glue output range of group A and group B, the qualified impeller speed range of group A and group B glue output pipes and the qualified impeller speed ratio range of group A and group B glue output pipes are preset respectively; The glue passes through the impellers on the glue outlet pipes of group A and group B and drives the impellers to rotate, and the speed data of the second gear is obtained in real time through the speed processing module, and the speed data of the impeller is obtained according to the speed data of the second gear; The control device compares the impeller rotation data with the corresponding preset qualified impeller rotation range in real time, and judges whether the liquid flow is abnormal according to the comparison result. If there is an abnormality, the The alarm device sounds an alarm.

6. The method for visually monitoring the glue output ratio of component A and component B according to claim 5, characterized in that: The determining whether the liquid flow rate is abnormal, and if so, the alarm device sounds an alarm, comprises: When the impeller revolutions on the rubber outlet pipe of group A, the impeller revolutions on the rubber outlet pipe of group B, and the ratio of the impeller revolutions on the rubber outlet pipes of group A to group B are all 0, it is in standby state, and the alarm device does not sound an alarm; When the impeller speed on the rubber outlet pipe of group A or the impeller speed on the rubber outlet pipe of group B is 0, the surface rubber pipe is blocked, and the alarm device sends out a first-level alarm; When either the impeller speed on the A group glue outlet pipe or the impeller speed on the B group glue outlet pipe is not within the qualified impeller speed range, or the impeller speed ratio of the A group and the B group glue outlet pipe is not within the qualified speed ratio range, the alarm device sends out a second level alarm.

7. The method for visually monitoring the glue output ratio of component A and component B according to claim 5, characterized in that: The first level alarm intensity is greater than the second level alarm intensity.

8. A visual method for monitoring the glue output ratio of component A and component B according to claim 5, characterized in that: It also includes a digital display device connected to the control device, and the digital display device is used to display the number of revolutions of the impellers in the respective liquid flow detection devices on the A group of rubber outlet pipes and the B group of rubber outlet pipes in real time.

9. The method for visually monitoring the glue output ratio of component A and component B according to claim 5, characterized in that: The control device adopts PLC.

10. The method for visually monitoring the glue output ratio of component A and component B according to claim 5, characterized in that: The glue passes through the impellers on the glue outlet pipe of group A and the glue outlet pipe of group B and drives the impellers to rotate, including: The glue filling port is opened, glue starts to flow out, and the impeller is pushed by the glue and starts to rotate; The glue filling port is closed and the glue discharge is completed. One glue discharge process lasts for 3 seconds. The number of revolutions of the impeller is obtained only during the discharge time.

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