Riveting and welding device for photovoltaic module junction box

Abstract

A riveting and welding device for a photovoltaic module junction box, comprising a plurality of riveting and welding units (2) and a rail unit (3), wherein the plurality of riveting and welding units (2) are in one-to-one correspondence with junction boxes (200) of a photovoltaic module (100), the riveting and welding units (2) can move on the rail unit (3) in the direction of a short side or a long side of the photovoltaic module, the riveting and welding unit (2) comprises a first frame and an image detection mechanism (21), a riveting mechanism (22) and a welding mechanism (23) which are arranged on the first frame, and the riveting mechanism (22) and the welding mechanism (23) can be raised and lowered separately on the rail unit (3). The riveting and welding device can improve the welding effect between photovoltaic module lead-out terminals and the junction boxes (200).

Description

Riveting device for photovoltaic module junction boxes

[0001] Cross-reference to related applications

[0002] This application claims priority to Chinese Utility Model Patent Application No. 202422516468.8, filed on October 17, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to the field of photovoltaic module technology, and specifically to a riveting and welding device for a photovoltaic module junction box. Background Technology

[0004] The junction box of a photovoltaic (PV) module connects to the solar cells within the module, allowing the current generated by the solar cells to be drawn out. Additionally, the junction box contains diodes to protect the circuitry of the solar cells. During PV module manufacturing, the lead terminals of the PV module are soldered to the junction box using a tin-soldering method. However, poor soldering can easily occur between the lead terminals and the junction box, potentially causing the diodes inside the junction box to fail or burn out, and even leading to the destruction of the entire PV module.

[0005] Based on the above, it is essential to provide a device that can improve the welding effect between the photovoltaic module lead terminals and the junction box.

[0006] Public content

[0007] This disclosure provides a riveting and welding device for a photovoltaic module junction box, which can improve the welding effect between the photovoltaic module lead wire terminals and the junction box.

[0008] The specific technical solution provided in this disclosure is as follows:

[0009] A riveting and welding device for a photovoltaic module junction box is provided, comprising multiple riveting and welding units and a track unit. Each riveting and welding unit corresponds to a junction box of the photovoltaic module. Each riveting and welding unit can move along the short or long side of the photovoltaic module on the track unit. Each riveting and welding unit includes an image detection mechanism, a riveting mechanism, and a welding mechanism. The riveting mechanism and the welding mechanism can be raised and lowered on the track unit, respectively.

[0010] As a preferred embodiment of the above solution, the track unit includes a long side track, a short side track, and a lifting track. The long side track extends along the long side of the photovoltaic module, and the short side track extends along the short side of the photovoltaic module. The long side track includes multiple first long side tracks, which are disposed on the short side tracks and can move along them. The riveting and welding unit corresponds to each of the first long side tracks. The lifting track is disposed on the first long side track and can move along it. The lifting track includes a first lifting track and a second lifting track. The riveting mechanism is disposed on the first lifting track and can move up and down along it, and the welding mechanism is disposed on the second lifting track and can move up and down along it.

[0011] As a preferred embodiment of the above scheme, the long side track further includes a second long side track, and the short side track is disposed on the second long side track and can move along the second long side track.

[0012] As a preferred embodiment of the above solution, the riveting and welding device for the photovoltaic module junction box further includes a control unit. The riveting and welding unit and the track unit are both connected to the control unit. The control unit is used to control the operation of the track unit, the riveting mechanism, and the welding mechanism based on the information detected by the image detection mechanism.

[0013] As a preferred embodiment of the above solution, the riveting device for the photovoltaic module junction box further includes a barcode scanning unit and a second frame. The barcode scanning unit and the track unit are mounted on the second frame. The barcode scanning unit is used to scan the barcode on the photovoltaic module and is connected to the control unit.

[0014] As a preferred embodiment of the above solution, the riveting mechanism includes a rivet feed head, a flipping component, a recovery cylinder, an upper three-jaw clamp, and a lower three-jaw clamp. The rivet feed head is used to clamp the rivet, the flipping component is used to drive the rivet feed head to flip, the recovery cylinder is connected to the upper three-jaw clamp, and the recovery cylinder and the upper three-jaw clamp can be raised and lowered by air pressure. The upper three-jaw clamp is used to clamp the rivet rod after the rivet feed head has flipped, and the lower three-jaw clamp is used to clamp the rivet cap after the recovery cylinder and the upper three-jaw clamp have descended.

[0015] As a preferred embodiment of the above solution, the riveting device for the photovoltaic module junction box further includes a feeding unit of the riveting mechanism. The feeding unit includes a vibratory feeder, a rivet conveying track, a screening area, a waiting area, and a rivet feeding pipe. The vibratory feeder is connected to the screening area via the rivet conveying track. The screening area is connected to the waiting area via the rivet conveying track. The waiting area is connected to the rivet feeding pipe, and the rivet feeding pipe is connected to the rivet feeding head.

[0016] As a preferred embodiment of the above solution, the riveting device for the photovoltaic module junction box further includes a waste material recycling unit of the riveting mechanism. The waste material recycling unit includes a recycling pipe and a waste material bin, and the recycling pipe connects the recycling pipe and the waste material bin.

[0017] As a preferred embodiment of the above solution, the welding mechanism includes a welding head, a solder feeding tube, an air blowing tube, a solder wire detection device, and a temperature controller. The solder feeding tube and the air blowing tube correspond to the welding head. The solder feeding tube is connected to the solder wire detection device. The welding head is connected to the temperature controller. The temperature controller and the solder wire detection device are connected to the control unit.

[0018] As a preferred embodiment of the above solution, the image detection mechanism is mounted on the second lifting track. The image detection mechanism includes a camera that captures images of the riveting hole positions, riveting effect, and welding effect and uploads them to the control unit.

[0019] As a preferred embodiment of the above solution, the riveting and welding device for the photovoltaic module junction box further includes a positioning unit connected to the control unit. The positioning unit includes a lifting mechanism that lifts the photovoltaic module on the production line for image detection, riveting, and welding. The lifting mechanism includes a lifting cylinder, a lifting plate, and a first support plate for supporting the photovoltaic module. The piston shaft of the lifting cylinder is connected to the lifting plate.

[0020] As a preferred embodiment of the above solution, the positioning unit further includes a straightening mechanism. The straightening mechanism and the first support plate are disposed on the lifting plate. The straightening mechanism includes a straightening cylinder, a straightening block, and an adjusting component. The adjusting component can adjust the position of the straightening cylinder and the straightening block according to the size of the photovoltaic module. The adjusting component includes an adjusting track and an adjusting plate. The position of the adjusting plate on the adjusting track can be adjusted according to the length of the photovoltaic module. The straightening cylinder and the straightening block are disposed on the adjusting plate. The adjusting plate is provided with a second support plate for supporting the photovoltaic module. The adjusting track and the second support plate extend along the long side of the photovoltaic module, and the first support plate extends along the short side of the photovoltaic module. The first support plate, the second support plate, and the straightening block are provided with buffers for the photovoltaic module.

[0021] As a preferred embodiment of the above solution, the adjusting track, the lifting plate, and the lifting cylinder are located below the production line. The adjusting track is provided with a connecting groove that extends along the length of the adjusting track. The adjusting plate is provided with a threaded hole. The adjusting plate and the adjusting track are fixedly connected by a threaded connector connecting the threaded hole and the connecting groove. The adjusting plate and the adjusting track can be released from fixation by adjusting the threaded connector.

[0022] As a preferred embodiment of the above solution, the second frame is provided with an alarm unit, which is connected to the control unit. The control unit includes a control cabinet, which is connected to the second frame. The control cabinet is provided with a control panel and a display screen. The control panel is used to control and debug the positioning unit, the riveting unit, and the track unit. The display screen is used to display the image detection effect of the image detection mechanism.

[0023] By utilizing the above technical solution, the riveting and welding device for photovoltaic module junction boxes provided in this embodiment of the present disclosure is based on a riveting and welding unit comprising a first frame and a riveting mechanism and a welding mechanism mounted on the first frame, i.e., the riveting mechanism and welding mechanism are designed as an integrated unit. This allows the lead terminals of the photovoltaic module to be riveted to the junction box first and then welded, thereby improving the problem of poor soldering between the lead terminals and the junction box. Furthermore, the riveting and welding are more efficient than operating two separate devices. In addition, the image detection mechanism can detect the riveting and welding effects under the action of the riveting and welding unit, which facilitates the precise positioning of the lead terminals and the junction box by the riveting and welding device, ensuring a firm connection and improving the yield of the photovoltaic module. Moreover, since the riveting and welding unit can move and rise and fall along the short or long side of the photovoltaic module on the track unit, the movement of the riveting mechanism and welding mechanism has a large adjustable range, enabling rapid and accurate positioning to the holes in the junction box for riveting and welding, resulting in high riveting and welding efficiency. This allows the riveting and welding unit to connect different lead terminals of the photovoltaic module to the junction box. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of this disclosure, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this disclosure. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 is a three-dimensional structural schematic diagram of a riveting and welding device for a photovoltaic module junction box provided in an embodiment of the present disclosure;

[0026] Figure 2 is a structural schematic diagram of Figure 1 from another angle;

[0027] Figure 3 is a top view of the structure shown in Figure 1;

[0028] Figure 4 is a schematic diagram of the riveting and welding unit and the track unit in a riveting and welding device provided in an embodiment of the present disclosure;

[0029] Figure 5 is a partial structural schematic diagram of Figure 4;

[0030] Figure 6 is a structural schematic diagram of Figure 5 from another angle;

[0031] Figure 7 is a partial structural schematic diagram of Figure 5;

[0032] Figure 8 is a schematic diagram of the positioning unit in a riveting and welding device provided in an embodiment of this disclosure. Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of this disclosure clearer, the technical solutions in the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this disclosure, and not all embodiments. Based on the embodiments in this disclosure, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this disclosure.

[0034] It should be noted that when an element is described as being "fixed to" another element, it can be directly on the other element, or one or more intermediate elements may exist between them. When an element is described as being "connected to" another element, it can be directly connected to the other element, or one or more intermediate elements may exist between them. The terms "vertical," "horizontal," "left," "right," "upper," "lower," "inner," "outer," "bottom," etc., used in this specification to indicate orientation or positional relationships are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing this disclosure and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this disclosure. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0035] In existing technologies, the lead terminals of photovoltaic modules are soldered to the junction box using a tin-adding soldering method, but this method is prone to defects such as cold solder joints. By setting rivet holes at the solder joints of the junction box, rivet the lead terminals to the rivet holes, and then performing tin-adding soldering in the rivet holes, the soldering effect between the lead terminals and the junction box can be enhanced, thereby improving the yield of photovoltaic modules.

[0036] Existing riveting and welding mechanisms for photovoltaic module junction boxes require separate movement operations, resulting in low riveting and welding efficiency. Furthermore, the limited adjustable range of movement of these mechanisms hinders quick and precise positioning of the junction box's holes for riveting or welding, further reducing efficiency. Additionally, image inspection of the riveting or welding process is necessary, but existing image inspection mechanisms are incomplete and cannot effectively control the module's clamping, leading to low yield rates for photovoltaic modules.

[0037] Based on the above, this disclosure provides a riveting and welding device for photovoltaic module junction boxes. This device can automatically rivet the lead terminals of the photovoltaic module to the junction box, followed by welding, to enhance the welding effect between the lead terminals and the junction box, thereby improving the yield of the photovoltaic module. Furthermore, the riveting mechanism and welding mechanism are integrated into a single design, improving the riveting and welding efficiency of the junction box. Simultaneously, the image detection mechanism enables comprehensive image detection, providing excellent control over the photovoltaic module and further improving its yield. The embodiments of this disclosure are explained in detail below.

[0038] As shown in Figures 1 to 4, the riveting device for the photovoltaic module junction box provided in this embodiment includes multiple riveting units 2 and a track unit 3. Each riveting unit 2 corresponds one-to-one with a junction box 200 of the photovoltaic module 100. The riveting unit 2 can move along the short or long side of the photovoltaic module on the track unit 3. Each riveting unit 2 includes a first frame (not shown) and an image detection mechanism 21, a riveting mechanism 22, and a welding mechanism 23 mounted on the first frame. The riveting mechanism 22 and the welding mechanism 23 can be raised and lowered on the track unit 3, respectively. The image detection mechanism 21 is used for image detection. For example, the image detection mechanism detects the riveting hole positions, riveting effect, and welding effect of the junction box. This allows for comprehensive image detection of the photovoltaic module's riveting process, providing good control over the photovoltaic module and improving its yield.

[0039] The riveting and welding device for photovoltaic module junction boxes provided in this embodiment is based on the riveting and welding unit 2, which includes a first frame and a riveting mechanism 22 and a welding mechanism 23 mounted on the first frame. That is, the riveting mechanism 22 and the welding mechanism 23 are designed as a single unit. This allows the photovoltaic module's lead-out terminals to be riveted to the junction box before welding, improving the problem of poor solder joints between the lead-out terminals and the junction box. Furthermore, the riveting and welding are more efficient than operating two separate devices. In addition, the image detection mechanism 21 can detect the riveting and welding effects under the action of the riveting and welding unit 2. This facilitates the precise positioning of the lead-out terminals and the junction box by the riveting and welding device, ensuring a firm connection and improving the yield of the photovoltaic module. In addition, since the riveting and welding unit 2 can move and rise and fall along the short or long side of the photovoltaic module on the track unit 3, the movement of the riveting mechanism 22 and the welding mechanism 23 has a large adjustable range, which can quickly and accurately position the hole of the junction box 200 to realize riveting and welding, and the riveting and welding efficiency is high. This is beneficial for the riveting and welding unit 2 to connect different lead terminals of the photovoltaic module to the junction box.

[0040] The riveting and welding device provided in this embodiment also includes a control unit (not shown). The riveting and welding unit 2 and the track unit 3 are both connected to the control unit. The control unit is used to control the operation of the track unit 3, the riveting mechanism 22 and the welding mechanism 23 based on the information detected by the image detection mechanism 21.

[0041] As shown in Figures 1, 4, and 5, the track unit 3 includes a long side track 31, a short side track 32, and a lifting track 33. The long side track 31 extends along the long side of the photovoltaic module, and the short side track 32 extends along the short side of the photovoltaic module. The long side track 31 includes multiple first long side tracks 311, which are mounted on the short side track 32 and can move along it. The riveting unit 2 corresponds one-to-one with the first long side track 311, and the lifting track 33 is mounted on the first long side track 311 and can move along it. The moving and lifting track 33 includes a first lifting track 331 and a second lifting track 332. A riveting mechanism 22 is mounted on the first lifting track 331 and can move up and down along it. A welding mechanism 23 is mounted on the second lifting track 332 and can move up and down along it. The first and second lifting tracks 331 and 332 allow the riveting and welding mechanisms to descend independently during riveting or welding operations. The short side track 32 allows the riveting and welding units 2 to move together along the short side of the photovoltaic module to adjust their position to match the junction box. The long side track 31 also includes a second long side track 312. The short side track 32 is mounted on and can move along the second long side track 312. The second long side track 312 allows the riveting and welding units 2 to move together along the long side of the photovoltaic module to roughly adjust their position to match the junction box. The first long side track 311 allows each riveting and welding unit 2 to move individually along the long side of the photovoltaic module to precisely adjust its position to match the junction box.

[0042] The riveting device for the photovoltaic module junction box also includes a second frame (not shown) and an alarm unit (not shown). The track unit and the alarm unit are mounted on the second frame, and the alarm unit is connected to the control unit. In this embodiment, the long side track 31, the short side track 32, and the lifting track 33 all include a slide rail, a motor 34, a lead screw, and a slider (not shown). The motor 34 is controlled by the control unit to rotate and drive the lead screw to rotate. The lead screw drives the slider connected to it to move. The slider moves along the slide rail. The second long side track 312 is mounted on the second frame. There are two second long side tracks 312, which are located on both sides of the photovoltaic module. There is one short side track 32 that spans across the photovoltaic module. The two ends of the short side track 32 move on the second long side track 312 via sliders. There are three first long side tracks 311. The first long side tracks 311 move on the short side tracks 32 via sliders. The first lifting track 331 and the second lifting track 332 are provided in three sets corresponding to the first long side track 311. Three lifting rails 331 and 332 are installed on the first frame, corresponding to the first long side rail 311. Each set of first lifting rails 331 and second lifting rails 332 is set on the corresponding first frame. The first frame moves on the corresponding first long side rail 311 via the slider of the corresponding first long side rail 311. Each photovoltaic module is provided with three junction boxes, which extend along the short side of the photovoltaic module. There are three riveting units 2, each corresponding to one of the three junction boxes. Each riveting unit 2 corresponds to a set of first lifting rails 331 and second lifting rails 332. The riveting mechanism 22 is set on the first lifting rail 331 via the slider of the first lifting rail 331 and moves up and down along the first lifting rail 331. The welding mechanism 23 and the image detection mechanism 21 are set on the second lifting rail 332 via the slider of the second lifting rail 332 and move up and down along the second lifting rail 332.

[0043] The second frame includes a frame 5 and a protective cover (not shown). The protective cover is fixed to the frame. The production line and positioning unit 1 are set on the frame. The alarm unit includes an alarm, which is set on the top of the protective cover. When there is an abnormality in the detection of the riveting hole position, the riveting effect, the welding effect, or the equipment, the alarm will be triggered by the control unit. The control unit includes a control cabinet, which is connected to the second frame. The control cabinet is equipped with a control panel and a display screen. The control panel is used to control and debug the positioning unit, the riveting and welding unit, and the track unit. The display screen is used to display the image detection effect of the image detection mechanism.

[0044] The riveting device for the photovoltaic module junction box also includes a barcode scanning unit (not shown). This unit scans the barcodes on the photovoltaic modules and is connected to the control unit. The unit is mounted on the second frame. In this embodiment, the scanning unit includes various sizes of barcode scanners, which are installed at the corners of the frame. The scanners scan the barcodes on the bottom of the photovoltaic modules, and process tracking is performed by identifying the barcode information, providing good traceability for the photovoltaic modules.

[0045] The riveting mechanism 22 includes a rivet feed head, a flipping component, a recovery cylinder, an upper three-jaw clamp, and a lower three-jaw clamp. The rivet feed head is used to clamp the rivet, the flipping component is used to drive the rivet feed head to flip, and the recovery cylinder is connected to the upper three-jaw clamp. The recovery cylinder and the upper three-jaw clamp can be raised and lowered by air pressure. The upper three-jaw clamp is used to clamp the rivet rod after the rivet feed head has flipped, and the lower three-jaw clamp is used to clamp the rivet cap after the recovery cylinder and the upper three-jaw clamp have descended. In this embodiment, the specific structure of the riveting mechanism is not shown in the figure. The riveting mechanism is connected to the control unit. The feeding head holds the rivet to be riveted. At this time, the rivet shank is facing down and the rivet head is facing up. During riveting, the flipping component drives the feeding head to rotate 180 degrees, so that the rivet shank is facing up and the rivet head is facing down. The rivet shank is held by the upper three-jaw chuck. Then, the recovery cylinder and the upper three-jaw chuck send the rivet to the lower three-jaw chuck by air pressure. The lower three-jaw chuck holds the rivet head, and the lower part of the rivet head extends into the riveting hole of the junction box. The recovery cylinder and the upper three-jaw chuck rise by air pressure and pull the rivet shank upward. The rivet head expands under force to achieve riveting. The rivet shank is pulled off and recovered by the recovery cylinder.

[0046] The riveting device for the photovoltaic module junction box also includes a feeding unit (not shown) of the riveting mechanism 22. The feeding unit is connected to the control unit and includes a vibratory feeder, a rivet conveying track, a screening area, a waiting area, and a rivet feeding pipe. The vibratory feeder is connected to the screening area through the rivet conveying track. The screening area is connected to the waiting area through the rivet conveying track. The waiting area is connected to the rivet feeding pipe, and the rivet feeding pipe is connected to the rivet feeding head. In this embodiment, the feeding unit is set on the frame below the riveting unit and the track unit. The screening area is equipped with a screening brush and a CCD camera. The screening brush can sweep away unqualified rivets to prevent defective rivets from flowing to the waiting area. The CCD camera is connected to the control unit to screen the rivet specifications and select qualified rivets to flow to the waiting area. The waiting area is equipped with a photoelectric sensor, which is connected to the control unit. When the photoelectric sensor detects that there are not enough rivets in the waiting area, the control unit controls the vibratory feeder to run and transport the rivets through the rivet conveying track. When the riveting mechanism needs to rivet, the control unit controls the waiting area to use high-pressure gas to feed rivets into the rivet feeding pipe. The rivet feeding pipe transports the rivets to the rivet feeding head with the rivet shank facing down and the rivet head facing up to achieve subsequent riveting.

[0047] Referring to Figures 1 and 7, the riveting device for the photovoltaic module junction box also includes a scrap material recovery unit for the riveting mechanism 22. The scrap material recovery unit is connected to the control unit and includes a recovery pipe (not shown) and a scrap material bin 242. The recovery pipe connects to the recovery cylinder, the scrap material bin 242, and a high-pressure air source. After riveting, excess nail rods are recovered into the scrap material bin 242 through the recovery cylinder and the recovery pipe. In this embodiment, the scrap material bin 242 is mounted on a frame on one side of the track unit 3. There are three scrap material bins 242, each corresponding to one of the three riveting mechanisms 22.

[0048] As shown in Figures 5 to 7, the welding mechanism 23 includes a welding head 231, a solder feed tube 232, an air blowing tube 233, a solder wire detection element (not shown), and a temperature controller (not shown). The solder feed tube 232 and the air blowing tube 233 correspond to the welding head 231. The solder feed tube 232 is connected to the solder wire detection element, and the welding head 231 is connected to the temperature controller. The temperature controller and the solder wire detection element are connected to the control unit. The solder feed tube 232 is also connected to an air clamp 234, which is connected to the control unit. During welding, the control unit controls the air clamp 234 to open, and the solder wire enters the solder feed tube 232 through the solder wire detection element. The solder feed tube 232 delivers the solder wire to the welding area of ​​the welding head 231. In this embodiment, the welding head 231 is an electric welding head. The electric welding head heats and contacts the solder wire, causing the solder wire to melt and cover the riveting area. Then, the air blowing tube 233 cools and solidifies the weld, completing the welding. The temperature controller is used to set the temperature of the electric welding head and can also monitor the welding temperature of the electric welding head in real time.

[0049] As shown in Figures 5 to 7, the image detection mechanism 21 includes an imaging component, which is mounted on the second lifting track 332. The imaging component captures images of the riveting hole positions, riveting effect, and welding effect and uploads them to the control unit. The control unit has an AI learning function for the images. After the control unit collects and identifies abnormal images, it sends them to the AI ​​for learning and storage, thereby improving the success rate of subsequent riveting or welding defects. In this embodiment, the imaging component is a CCD camera, and the image detection mechanism 21 is also connected to a MES system (Manufacturing Execution System), enabling the riveting and welding device of this disclosure to have good control over the riveting and welding quality of photovoltaic modules.

[0050] As shown in Figures 1 and 8, the riveting and welding device provided in this embodiment further includes a positioning unit 1, which is connected to a control unit. The positioning unit 1 includes a lifting mechanism 11, which lifts the photovoltaic modules on the production line for image detection, riveting, and welding. As shown in Figure 8, the lifting mechanism 11 includes a lifting cylinder 111, a lifting plate 112, and a first support plate 113 for supporting the photovoltaic modules. The piston shaft of the lifting cylinder 111 is connected to the lifting plate 112. The positioning unit 1 also includes a straightening mechanism 12, which and the first support plate 113 are disposed on the lifting plate 112. The straightening mechanism 12 includes a straightening cylinder 121, a straightening block 122, and an adjusting member. The adjusting member can adjust the position of the straightening cylinder 121 and the straightening block 122 according to the size of the photovoltaic modules. The adjusting components include an adjusting track 123 and an adjusting plate 124. The position of the adjusting plate 124 on the adjusting track 123 can be adjusted according to the length of the photovoltaic module. A straightening cylinder 121 and a straightening block 122 are disposed on the adjusting plate 124. A second support plate 125 for supporting the photovoltaic module is provided on the adjusting plate 124. The adjusting track 123 and the second support plate 125 extend along the long side of the photovoltaic module, and the first support plate 113 extends along the short side of the photovoltaic module. A buffer 101 for the photovoltaic module is provided on the first support plate 113, the second support plate 125 and the straightening block 122. The buffer 101 is used for buffering during the support and straightening of the photovoltaic module to avoid damage to the photovoltaic module.

[0051] In this embodiment, there are several adjustment tracks 123, two adjustment plates 124, which are respectively set on both sides of the photovoltaic module in the length direction. There are several first support plates 113 located between the two adjustment plates 124. The first support plates 113 are fixed on the adjustment tracks 123. Each adjustment plate 124 is provided with several second support plates 125, two correction cylinders 121 and correction blocks 122 corresponding to the short side of the photovoltaic module, and two correction cylinders 121 and correction blocks 122 corresponding to the long side of the photovoltaic module. The second support plates 125 support both ends of the photovoltaic module in the length direction, so as to achieve more stable support for the photovoltaic module. The adjusting track 123, the lifting plate 112, and the lifting cylinder 111 are located below the assembly line. The adjusting track 123 is provided with a connecting groove 126, which extends along the length of the adjusting track 123. The adjusting plate 124 is provided with a threaded hole (not shown). The adjusting plate 124 and the adjusting track 123 are fixedly connected by connecting the threaded hole and the connecting groove 126 through a threaded connector 4. The adjusting plate 124 and the adjusting track 123 are released from fixation by adjusting the threaded connector 4. According to the length of the photovoltaic module, manually adjust the fixed position of the adjustment plate 124 on the adjustment track 123. Specifically, loosen the threaded connector 4 on the adjustment plate 124, and the lower end of the threaded connector 4 disengages from the connecting groove 126, thereby releasing the fixation between the adjustment plate 124 and the adjustment track 123. Then, move the adjustment plate 124 along the adjustment track 123. After moving to the appropriate position, tighten the threaded connector 4. The lower end of the threaded connector 4 extends into the connecting groove 126 and is interference-fitted with the connecting groove 126, thereby fastening the adjustment plate 124 on the adjustment track 123 and completing the adjustment.

[0052] It is worth noting that before use, the riveting and welding device disclosed herein will adjust the position of the alignment mechanism 12 and the junction box according to the size of different photovoltaic modules. After adjustment, the alignment coordinates of the alignment mechanism 12 and the coordinates of the junction box will be input to the control unit. When the riveting and welding device is officially used, after the photovoltaic modules flow in through the assembly line, the alignment mechanism 12, the riveting and welding unit 2, and the track unit 3 will perform operations according to the coordinates of the corresponding photovoltaic module size in the control unit.

[0053] Before the riveting operation, the riveting device disclosed herein has three junction boxes at the intermediate busbar of the photovoltaic module 100. Each junction box has two riveting holes and two lead-out terminal through holes corresponding to the riveting holes on its copper sheet. The intermediate busbar has lead-out terminals bent upwards, which are also made of copper sheets. After passing through the lead-out terminal through holes, the lead-out terminals are bent and abut against the copper sheets of the junction boxes. The lead-out terminals have through holes corresponding to the riveting holes. During the riveting operation, the photovoltaic module 100 flows into the positioning unit 1 from the feed inlet 301 through the conveyor line 300. The sensor of the conveyor line senses that the photovoltaic module has reached the designated position. When the control unit receives a signal, it controls the alignment mechanism 12 to align and position the photovoltaic module, and the lifting mechanism 11 to lift the photovoltaic module. Then, the control unit controls the riveting unit 2 to move along the short or long side of the photovoltaic module on the track unit 3 to a position above the junction box 200. At this time, the image detection mechanism 21 first performs image detection on the riveting hole position of the junction box (the alignment state of the through hole of the lead wire terminal and the riveting hole of the junction box) and transmits the image detection result to the control unit. If the riveting hole position is normal, the control unit gives an OK signal and controls the riveting mechanism 22 to descend on the track unit 3 to rivet the riveting hole position of the junction box.

[0054] During riveting, the rivet is fed to the feeding head with the rivet shank facing down and the rivet head facing up by the feeding tube. The feeding head flips, and the recovery cylinder and upper three-jaw chuck descend under air pressure. The lower part of the rivet head extends into the riveting hole of the junction box. The recovery cylinder and upper three-jaw chuck rise under air pressure and pull the rivet shank upward. The rivet head expands under force, thus riveting the lead wire terminal and the copper sheet of the junction box. The rivet shank is broken off and recovered by the recovery cylinder and the waste material recovery unit. Each junction box has two riveting holes. Each riveting mechanism 22 rivets and fixes the rivet in two stages. When switching holes, the riveting mechanism 22 moves up and down on the track unit 3. The device can move along the short or long side of the photovoltaic module. If the riveting hole is abnormal, the control unit will give an abnormal signal to trigger the alarm and control the riveting mechanism 22 to not rivet the hole. That is, when one riveting hole of the junction box is abnormal, the control unit can control the riveting mechanism 22 to skip the riveting hole. If all the riveting holes of the junction boxes are abnormal, the control unit will give an abnormal signal to trigger the alarm and control the correction mechanism 12 to open and the lifting mechanism 11 to drive the photovoltaic module to descend. The photovoltaic module is directly transferred from the production line to be manually inspected.

[0055] After riveting is completed, the image detection mechanism 21 moves along the short or long side of the photovoltaic module on the track unit 3 to detect the riveting effect on the junction box and transmits the image detection effect to the control unit. If the riveting effect is normal, the control unit gives an OK signal and controls the welding mechanism 23 to descend on the track unit 3 to weld the holes of the junction box. Each welding mechanism 23 welds twice. When switching welding points, the welding mechanism 23 moves up and down on the track unit 3 or along the short or long side of the photovoltaic module. If the riveting effect is abnormal, the control unit gives an abnormal signal to trigger the alarm and controls the welding mechanism 23 not to weld at that point (skip the point). If the riveting effect of all junction boxes is abnormal, the control unit gives an abnormal signal to trigger the alarm and controls the lifting mechanism 11 to drive the photovoltaic module to descend. The photovoltaic module is directly transferred from the production line to be manually inspected.

[0056] After welding is completed, the image inspection mechanism 21 moves along the short or long side of the photovoltaic module on the track unit 3 to inspect the welding effect on the junction box and transmits the image inspection result to the control unit. If the welding effect is normal, the control unit gives an OK signal; if the welding effect is abnormal, the control unit gives an abnormal signal to trigger the alarm. Finally, the control unit controls the lifting mechanism 11 to lower the photovoltaic module. The photovoltaic module is passed down from the discharge port 302 by the production line. Photovoltaic modules with abnormal welding effect are handed over to manual inspection.

[0057] Through the above process, the multiple riveting and welding units 2 of this disclosure correspond one-to-one with the junction boxes of the photovoltaic modules, and can simultaneously rivet or weld the junction boxes of the photovoltaic modules. The riveting mechanism 22 and the welding mechanism 23 can move together along the short or long side of the photovoltaic module and descend separately to perform riveting or welding. The movement of the riveting mechanism and the welding mechanism has a large adjustable range, which can quickly and accurately locate the holes of the junction box to achieve riveting or welding. The riveting and welding efficiency is high. At the same time, the image detection mechanism 21 of this disclosure can perform image detection on the riveting hole position, riveting effect and welding effect. The image detection is comprehensive, which can achieve good control of the photovoltaic modules and improve the yield of the photovoltaic module junction boxes.

[0058] Although preferred embodiments of the present disclosure have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the present disclosure.

[0059] Obviously, those skilled in the art can make various modifications and variations to this disclosure without departing from its spirit and scope. Therefore, if such modifications and variations fall within the scope of the claims of this disclosure and their equivalents, this disclosure is also intended to include such modifications and variations.

Claims

1. A riveting device for a junction box of a photovoltaic module, wherein, It includes multiple riveting and welding units and track units. The multiple riveting and welding units are used to correspond one-to-one with the junction boxes of photovoltaic modules. The riveting and welding units can move along the short or long side of the photovoltaic module on the track units. The riveting and welding unit includes a first frame and an image detection mechanism, a riveting mechanism and a welding mechanism disposed on the first frame. The riveting mechanism and the welding mechanism can be raised and lowered on the track units respectively.

2. The riveting device for photovoltaic module junction boxes according to claim 1, wherein, The track unit includes a long side track, a short side track, and a lifting track. The long side track extends along the long side of the photovoltaic module, and the short side track extends along the short side of the photovoltaic module. The long side track includes multiple first long side tracks, which are disposed on the short side tracks and can move along them. The riveting and welding unit corresponds to each of the first long side tracks. The lifting track is disposed on the first long side track and can move along it. The lifting track includes a first lifting track and a second lifting track. The riveting mechanism is disposed on the first lifting track and can move up and down along it, and the welding mechanism is disposed on the second lifting track and can move up and down along it.

3. The riveting device for photovoltaic module junction boxes according to claim 2, wherein, The long side track also includes a second long side track, and the short side track is disposed on the second long side track and can move along the second long side track.

4. The riveting apparatus for photovoltaic module junction boxes according to claim 1, wherein, It also includes a control unit, which is connected to both the riveting and welding unit and the track unit. The control unit is used to control the operation of the track unit, the riveting mechanism and the welding mechanism based on the information detected by the image detection mechanism.

5. The riveting apparatus for photovoltaic module junction boxes according to claim 4, wherein, It also includes a barcode scanning unit and a second frame. The barcode scanning unit and the track unit are mounted on the second frame. The barcode scanning unit is used to scan the barcode on the photovoltaic module and is connected to the control unit.

6. The riveting apparatus for photovoltaic module junction boxes according to claim 1, wherein, The riveting mechanism includes a rivet feed head, a flipping component, a recovery cylinder, an upper three-jaw clamp, and a lower three-jaw clamp. The rivet feed head is used to clamp the rivet, the flipping component is used to drive the rivet feed head to flip, the recovery cylinder is connected to the upper three-jaw clamp, and the recovery cylinder and the upper three-jaw clamp can be raised and lowered by air pressure. The upper three-jaw clamp is used to clamp the rivet rod after the rivet feed head has flipped, and the lower three-jaw clamp is used to clamp the rivet cap after the recovery cylinder and the upper three-jaw clamp have descended.

7. The riveting apparatus for photovoltaic module junction boxes according to claim 6, wherein, It also includes a feeding unit for the riveting mechanism. The feeding unit includes a vibratory feeder, a rivet conveying track, a screening area, a waiting area, and a rivet feeding pipe. The vibratory feeder is connected to the screening area through the rivet conveying track. The screening area is connected to the waiting area through the rivet conveying track. The waiting area is connected to the rivet feeding pipe, and the rivet feeding pipe is connected to the rivet feeding head.

8. The riveting apparatus for photovoltaic module junction boxes according to claim 6, wherein, It also includes a waste material recycling unit for the riveting mechanism, the waste material recycling unit including a recycling pipe and a waste material bucket, the recycling pipe connecting the recycling pipe and the waste material bucket.

9. The riveting apparatus for photovoltaic module junction boxes according to claim 4, wherein, The welding mechanism includes a welding head, a solder feeding tube, an air blowing tube, a solder wire detection device, and a temperature controller. The solder feeding tube and the air blowing tube correspond to the welding head. The solder feeding tube is connected to the solder wire detection device. The welding head is connected to the temperature controller. The temperature controller and the solder wire detection device are connected to the control unit.

10. The riveting device for photovoltaic module junction boxes according to claim 2, wherein, The image detection mechanism is mounted on the second lifting track, and the image detection mechanism includes a camera component for taking pictures.

11. The riveting device for photovoltaic module junction boxes according to claim 4, wherein, It also includes a positioning unit connected to the control unit. The positioning unit includes a lifting mechanism that lifts the photovoltaic modules on the production line for image detection, riveting, and welding. The lifting mechanism includes a lifting cylinder, a lifting plate, and a first support plate for supporting the photovoltaic modules. The piston shaft of the lifting cylinder is connected to the lifting plate.

12. The riveting apparatus for photovoltaic module junction boxes according to claim 11, wherein, The positioning unit further includes a straightening mechanism, which is disposed on the lifting plate along with the first support plate. The straightening mechanism includes a straightening cylinder, a straightening block, and an adjusting component. The adjusting component can adjust the position of the straightening cylinder and the straightening block according to the size of the photovoltaic module. The adjusting component includes an adjusting track and an adjusting plate. The position of the adjusting plate on the adjusting track can be adjusted according to the length of the photovoltaic module. The straightening cylinder and the straightening block are disposed on the adjusting plate. The adjusting plate is provided with a second support plate for supporting the photovoltaic module. The adjusting track and the second support plate extend along the long side of the photovoltaic module, and the first support plate extends along the short side of the photovoltaic module. The first support plate, the second support plate, and the straightening block are provided with buffers for the photovoltaic module.

13. The riveting apparatus for photovoltaic module junction boxes according to claim 12, wherein, The adjusting track, the lifting plate, and the lifting cylinder are located below the production line. The adjusting track is provided with a connecting groove that extends along the length of the adjusting track. The adjusting plate is provided with a threaded hole. The adjusting plate and the adjusting track are fixedly connected by a threaded connector connecting the threaded hole and the connecting groove. The adjusting plate and the adjusting track can be released by adjusting the threaded connector.

14. The riveting apparatus for photovoltaic module junction boxes according to claim 5, wherein, The second frame is equipped with an alarm unit, which is connected to the control unit. The control unit includes a control cabinet, which is connected to the second frame. The control cabinet is equipped with a control panel and a display screen. The control panel is used to control and debug the riveting unit and the track unit, and the display screen is used to display the image detection effect of the image detection mechanism.

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