Manufacturing device for solar panel, manufacturing method for solar panel, positioning mechanism, and positioning method

Abstract

This manufacturing device for a solar panel comprises a positioning mechanism (10) for positioning a plurality of solar cells (60). The positioning mechanism (10) has a base plate (11), a first connection member (13a), a plurality of first support members (13b), a plurality of second support members (14a), a first drive mechanism (13c), and a second drive mechanism (14c). The first connection member (13a) extends along a first direction. The plurality of first support members (13b) are connected to the first connection member (13a) so as to be arranged at intervals along the first direction. The first drive mechanism (13c) is connected to the first connection member (13a) and presses the plurality of first support members (13b) against the respective plurality of solar cells (60) by moving the first connection member (13a) along the first direction. The plurality of second support members (14a) are attached to the base plate (11) so as to be arranged at intervals along the first direction.

Description

Manufacturing apparatus for solar cell panel, manufacturing method for solar cell panel, positioning mechanism, and positioning method

[0001] The present disclosure relates to a manufacturing apparatus for a solar cell panel, a manufacturing method for a solar cell panel, a positioning mechanism, and a positioning method.

[0002] International Publication No. 2013 / 128568 (Patent Document 1) describes a manufacturing apparatus for a solar cell panel. In the manufacturing apparatus for a solar cell panel described in Patent Document 1, solar cells are mounted on a station one by one and positioned by pressing against a reference block.

[0003] International Publication No. 2013 / 128568

[0004] In the manufacturing apparatus for a solar cell panel described in Patent Document 1, since the positioning of solar cells is performed one by one, it is difficult to simultaneously position a plurality of solar cells or adjust the interval between two adjacent solar cells. As a result, according to the manufacturing apparatus for a solar cell panel described in Patent Document 1, the manufacturing time of the solar cell panel increases.

[0005] The present disclosure has been made in view of the problems of the prior art as described above. More specifically, the present disclosure provides a manufacturing apparatus for a solar cell panel capable of simultaneously positioning a plurality of solar cells.

[0006] The solar panel manufacturing apparatus of this disclosure includes a positioning mechanism. The positioning mechanism includes a base plate, a first connecting member, a plurality of first support members, a plurality of second support members, a first drive mechanism, and a second drive mechanism. A plurality of solar cells are arranged on the base plate. The first connecting member extends along a first direction. The plurality of first support members are connected to the first connecting member so as to be spaced apart along the first direction. The first drive mechanism is connected to the first connecting member and moves the first connecting member along the first direction, thereby pressing each of the plurality of first support members against each of the plurality of solar cells. The plurality of second support members are attached to the base plate so as to be spaced apart along the first direction. The second drive mechanism is connected to the base plate and moves the base plate along a second direction perpendicular to the first direction, thereby pressing each of the plurality of second support members against each of the plurality of solar cells.

[0007] According to the solar panel manufacturing apparatus of this disclosure, multiple solar cells can be positioned simultaneously.

[0008] This is a schematic diagram of the manufacturing apparatus 100. This is a plan view of the positioning mechanism 10. This is a partial perspective view of the positioning mechanism 10. This is a side view of the positioning mechanism 10. This is a side view of the holding mechanism 20. This is a plan view of the holding mechanism 20. This is a first side view of the coating mechanism 30. This is a second side view of the coating mechanism 30. This is a side view of the transport mechanism 40. This is a process diagram showing a method for manufacturing a solar cell panel using the manufacturing apparatus 100. This is a detailed process diagram of the solar cell positioning process S2. This is a side view illustrating the positioning mechanism lowering process S21. This is a plan view illustrating the first pressing process S23. This is a plan view illustrating the second pressing process S24. This is a first plan view illustrating the third pressing process S25. This is an enlarged plan view of the support member 15b in the first state. This is an enlarged plan view of the support member 15b in the second state. This is an enlarged plan view of the support member 15b in the third state. This is an enlarged plan view of the support member 15b in the fourth state. This is an enlarged plan view of the support member 15b in the fifth state. This is a schematic graph showing the relationship between the amount of movement of the connecting member 15a in the X direction and the rotation angle of the support member 15b. This is a schematic graph showing the relationship between the amount of movement of the connecting member 15a in the X direction and the force with which the support member 15b is pressed against the solar cell 60. This is an example of a plan view showing a state in which multiple solar cells 60 are arranged on a panel member 80. This is an enlarged plan view of a modified example of the connecting member 15a in the first state. This is an enlarged plan view of a modified example of the connecting member 15a in the second state. This is an enlarged plan view of a modified example of the connecting member 15a in the third state. This is an enlarged plan view of a modified example of the connecting member 15a in the fourth state. This is an enlarged plan view of a modified example of the connecting member 15a in the fifth state. This is a second plan view illustrating the third pressing process S25. This is a side view illustrating the adhesive application process S3. This is a plan view illustrating the adhesive application process S3. This is a first side view illustrating the solar cell inversion process S4. This is a second side view illustrating the solar cell inversion process S4. This is a side view illustrating the solar cell transport process S5. This is a plan view of the positioning mechanism 10 in the manufacturing apparatus 200. This is a cross-sectional view taken from XXVI-XXVI. This is the first explanatory diagram illustrating the operation of the manufacturing apparatus 200. This is the second explanatory diagram illustrating the operation of the manufacturing apparatus 200.

[0009] The embodiments of this disclosure will be described in detail with reference to the drawings. In the following drawings, the same or corresponding parts are denoted by the same reference numerals, and redundant descriptions will not be repeated.

[0010] Embodiment 1. The solar panel manufacturing apparatus according to Embodiment 1 will be described. The solar panel manufacturing apparatus according to Embodiment 1 will be referred to as manufacturing apparatus 100.

[0011] (Configuration of the manufacturing apparatus 100) The configuration of the manufacturing apparatus 100 is described below.

[0012] <Outline Configuration of Manufacturing Apparatus 100> Figure 1 is a schematic diagram of the manufacturing apparatus 100. As shown in Figure 1, the manufacturing apparatus 100 includes a positioning mechanism 10, a holding mechanism 20, a coating mechanism 30, a transport mechanism 40, and a controller 50. The positioning mechanism 10 positions multiple workpieces, which are solar cells 60. The holding mechanism 20 holds the multiple solar cells 60. The coating mechanism 30 applies adhesive 70 to each of the positioned multiple solar cells 60. The transport mechanism 40 transports the positioned and adhesive-coated multiple solar cells 60 onto the panel member 80. The controller 50 controls the positioning mechanism 10, the holding mechanism 20, the coating mechanism 30, and the transport mechanism 40.

[0013] <Configuration of Positioning Mechanism 10> Figure 2A is a plan view of the positioning mechanism 10. Figure 2B is a partial perspective view of the positioning mechanism 10. As shown in Figures 2A and 2B, the positioning mechanism 10 has a base plate 11. The base plate 11 has a first surface 11a and a second surface 11b. The second surface 11b is the opposite surface of the first surface 11a. The first surface 11a and the second surface 11b form the end faces of the base plate 11 in the thickness direction. Figure 1 shows a plan view of the positioning mechanism 10 as seen from the first surface 11a side.

[0014] The base plate 11 is, for example, rectangular in plan view. In plan view, the long and short sides of the base plate 11 extend along the X and Y directions, respectively. Each of the X and Y directions is perpendicular to the Z direction. The X and Y directions are perpendicular to each other. One of the X and Y directions may be referred to as the first direction, and the other as the second direction. The Z direction is aligned with the direction of gravity, i.e., the vertical direction. An opening 11c is formed in the base plate 11. The opening 11c is located in the center of the base plate 11 in plan view. The opening 11c is rectangular in plan view. In plan view, the long and short sides of the opening 11c extend along the X and Y directions, respectively.

[0015] The positioning mechanism 10 further includes a linear guide 12a and a linear guide 12b. The base plate 11 is attached to the linear guides 12a and 12b so as to be movable along the Y direction. The linear guides 12a and 12b are attached to both ends of the second surface 11b in the X direction.

[0016] The positioning mechanism 10 further includes a connecting member 13a, a plurality of support members 13b, and a drive mechanism 13c. The connecting member 13a, the support members 13b, and the drive mechanism 13c may be referred to as the first connecting member, the first support member, and the first drive mechanism, respectively. The connecting member 13a extends along the X direction on the first surface 11a. Each of the plurality of support members 13b has, for example, a connecting member 13ba and two cam followers 13bb. The connecting member 13ba extends along the Y direction. The two cam followers 13bb are each attached to both ends of the connecting member 13ba in the Y direction. The plurality of support members 13b are connected to the connecting member 13a so as to be spaced apart along the X direction. Each of the plurality of support members 13b is connected to the connecting member 13a at the connecting member 13ba.

[0017] The outer ring of the cam follower 13bb is preferably made of a material with high hardness as a measure against wear. As a measure against wear, the outer surface of the outer ring of the cam follower 13bb may be surface-treated. Furthermore, since the positioning accuracy is determined by the machining accuracy of the outer surface of the cam follower 13bb, the machining accuracy of the outer surface of the cam follower 13bb is appropriately determined based on the required positioning accuracy.

[0018] The drive mechanism 13c includes, for example, a motor 13ca and a ball screw 13cb. The rotation axis of the motor 13ca is connected to the screw axis of the ball screw 13cb. The screw axis of the ball screw 13cb is rotated by the rotation axis of the motor 13ca. The nut of the ball screw 13cb is connected to a connecting member 13a. The nut of the ball screw 13cb moves forward and backward along the X direction as the screw axis of the ball screw 13cb rotates. Therefore, the drive mechanism 13c can move the connecting member 13a along the X direction.

[0019] The positioning mechanism 10 further has a plurality of support members 14a. The support members 14a may be referred to as second support members. The plurality of support members 14a are arranged at intervals along the X direction. Each of the plurality of support members 14a is attached to the base plate 11. More specifically, the plurality of support members 14a are attached to the inner wall surface of the opening 11c along one of the long sides (first long side) of the opening 11c. Each of the plurality of support members 14a is, for example, a cam follower. The positioning mechanism 10 may further have a plurality of support members 14b. The plurality of support members 14b are arranged at intervals along the X direction. Each of the plurality of support members 14b is attached to the base plate 11. More specifically, the plurality of support members 14b are attached to the inner wall surface of the opening 11c along another long side (second long side) of the opening 11c. From another perspective, the multiple support members 14b are located on the opposite side from the multiple support members 14a with respect to the central position of the base plate 11 in the Y direction.

[0020] Each of the multiple support members 14b is, for example, a cam follower. The outer ring of the cam follower used in the support member 14b is preferably made of a material with high hardness as a measure against wear. As a measure against wear, the outer surface of the outer ring of the cam follower may be surface-treated. Furthermore, since the positioning accuracy is determined by the machining accuracy of the outer surface of the cam follower, the machining accuracy of the outer surface of the cam follower is appropriately determined based on the required positioning accuracy.

[0021] The positioning mechanism 10 further includes a drive mechanism 14c. The drive mechanism 14c is sometimes referred to as a second drive mechanism. The drive mechanism 14c includes, for example, a motor 14ca and a ball screw 14cb. The rotation axis of the motor 14ca is connected to the screw axis of the ball screw 14cb. The screw axis of the ball screw 14cb is rotated by the rotation axis of the motor 14ca. The nut of the ball screw 14cb is connected to the base plate 11. The nut of the ball screw 14cb moves forward and backward along the Y direction as the screw axis of the ball screw 14cb rotates. Therefore, the drive mechanism 14c can move the base plate 11 along the Y direction.

[0022] The positioning mechanism 10 may further include a connecting member 15a, a plurality of support members 15b, a plurality of elastic members 15c, and a drive mechanism 15d. The connecting member 15a, the support members 15b, and the drive mechanism 15d may be referred to as the second connecting member, the third support member, and the third drive mechanism, respectively. The connecting member 15a extends along the X direction. The plurality of support members 15b are spaced apart along the X direction. Each of the plurality of support members 15b is mounted on the first surface 11a along the second long side of the opening 11c so as to be rotatable in the XY plane (a plane perpendicular to the Z direction). That is, the connecting member 15a, the plurality of support members 15b, the plurality of elastic members 15c, and the drive mechanism 15d are located on the opposite side of the plurality of support members 14a in the Y direction.

[0023] Each of the multiple support members 15b has a connecting member 15ba, a hinge pin 15bb, and a cam follower 15bc. The connecting member 15ba has a connecting portion, a first portion, and a second portion. The first portion of the connecting member 15ba extends from the connecting portion of the connecting member 15ba along the X direction. The second portion of the connecting member 15ba extends from the connecting portion of the connecting member 15ba along the Y direction. In other words, the connecting member 15ba is L-shaped in plan view. However, the planar shape of the connecting member 15ba is not limited to this. The hinge pin 15bb extends along the Z direction. The connecting member 15ba is attached to the base plate 11 (first surface 11a) by the hinge pin 15bb at the connecting portion of the connecting member 15ba so as to be rotatable about the central axis of the hinge pin 15bb.

[0024] The cam follower 15bc is attached, for example, to the tip of the first portion of the connecting member 15ba. Each of the plurality of elastic members 15c connects the connecting member 15a to each of the connecting members 15ba of the plurality of support members 15b. The elastic member 15c is connected, for example, to the tip of the second portion of the connecting member 15ba. The tip of the second portion of the connecting member 15ba may have an arc-shaped chamfer centered on the position where the elastic member 15c is connected.

[0025] The drive mechanism 15d includes, for example, a motor 15da and a ball screw 15db. The rotation axis of the motor 15da is connected to the screw axis of the ball screw 15db. The screw axis of the ball screw 15db is rotated by the rotation axis of the motor 15da. The nut of the ball screw 15db is connected to the connecting member 15a. The nut of the ball screw 15db moves forward and backward along the X direction as the screw axis of the ball screw 15db rotates. Therefore, the drive mechanism 15d can move the connecting member 15a along the X direction. As the connecting member 15a moves forward and backward along the X direction, the connecting member 15ba rotates around the central axis of the hinge pin 15bb.

[0026] The positioning mechanism 10 may further include a connecting member 16a, a plurality of support members 16b, a plurality of elastic members 16c, and a drive mechanism 16d. The connecting member 16a extends along the X direction. The plurality of support members 16b are spaced apart along the X direction. Each of the plurality of support members 16b is mounted on the first surface 11a along the first long side of the opening 11c so as to be rotatable in the XY plane (a plane perpendicular to the Z direction). That is, the connecting member 16a, the plurality of support members 16b, the plurality of elastic members 16c, and the drive mechanism 16d are located on the opposite side of the plurality of support members 14b in the Y direction.

[0027] Each of the multiple support members 16b has a connecting member 16ba, a hinge pin 16bb, and a cam follower 16bc. The connecting member 16ba has a connecting portion, a first portion, and a second portion. The first portion of the connecting member 16ba extends from the connecting portion of the connecting member 16ba along the X direction. The second portion of the connecting member 16ba extends from the connecting portion of the connecting member 16ba along the Y direction. In other words, the connecting member 16ba is L-shaped in plan view. However, the planar shape of the connecting member 16ba is not limited to this. The hinge pin 16bb extends along the Z direction. The connecting member 16ba is attached to the base plate 11 (first surface 11a) by the hinge pin 16bb at the connecting portion of the connecting member 16ba so as to be rotatable around the central axis of the hinge pin 16bb.

[0028] The cam follower 16bc is attached, for example, to the tip of the first portion of the connecting member 16ba. Each of the plurality of elastic members 16c connects the connecting member 16a to each of the connecting members 16ba of the plurality of support members 16b. The elastic member 16c is connected, for example, to the tip of the second portion of the connecting member 16ba. The tip of the second portion of the connecting member 16ba may have an arc-shaped chamfer centered on the position where the elastic member 16c is connected.

[0029] The drive mechanism 16d includes, for example, a motor 16da and a ball screw 16db. The rotation axis of the motor 16da is connected to the screw axis of the ball screw 16db. The screw axis of the ball screw 16db is rotated by the rotation axis of the motor 16da. The nut of the ball screw 16db is connected to the connecting member 16a. The nut of the ball screw 16db moves forward and backward along the X direction as the screw axis of the ball screw 16db rotates. Therefore, the drive mechanism 16d can move the connecting member 16a along the X direction. As the connecting member 16a moves forward and backward along the X direction, the connecting member 16ba rotates around the central axis of the hinge pin 16bb.

[0030] Figure 3 is a side view of the positioning mechanism 10. As shown in Figure 3, the positioning mechanism 10 has a lifting shaft 17. The base plate 11 is connected to the lifting shaft 17 such that the second surface 11b faces downward in the Z direction. The lifting shaft 17 has, for example, a lifting motor with a ball screw, which moves the base plate 11 along the Z direction.

[0031] Figure 4 is a side view of the holding mechanism 20. Figure 5 is a top view of the holding mechanism 20. As shown in Figures 4 and 5, the holding mechanism 20 has a plurality of suction blocks 21. A solar cell 60 is placed on each of the plurality of suction blocks 21. A suction port 22 is connected to each of the plurality of suction blocks 21. When air is drawn in from the suction port 22 with the solar cell 60 in place, the solar cell 60 is attracted to and held by each of the plurality of suction blocks 21. Although not shown, the holding mechanism 20 has, for example, a linear motion robot as a mechanism for moving the plurality of suction blocks 21.

[0032] <Configuration of the coating mechanism 30> Figure 6 is a first side view of the coating mechanism 30. As shown in Figure 6, the coating mechanism 30 has a drive shaft 31, a drive shaft 32, a drive shaft 33, and a dispenser 34. The drive shaft 32 is attached to the drive shaft 31. The drive shaft 31 moves the drive shaft 32 along the X direction. The drive shaft 33 is attached to the drive shaft 32. The drive shaft 32 moves the drive shaft 33 along the Y direction. The dispenser 34 is attached to the drive shaft 33. The drive shaft 33 moves the dispenser 34 along the Z direction. In this way, the position of the dispenser 34 in the X, Y, and Z directions is moved by the drive shaft 31, the drive shaft 32, and the drive shaft 33. As the dispenser 34 supplies adhesive 70 with this movement, the coating mechanism 30 can apply adhesive 70 to the solar cell 60. Although not shown in the figures, the coating mechanism 30 may have a plurality of dispensers 34.

[0033] Figure 7 is a second side view of the coating mechanism 30. As shown in Figure 7, the coating mechanism 30 further includes a rotating shaft 35, a plurality of suction blocks 36, a lifting shaft 37, and a drive mechanism 38. The rotating shaft 35 extends along the X direction. The plurality of suction blocks 36 are attached to the rotating shaft 35 so as to be spaced apart along the X direction. Each of the plurality of suction blocks 36 is connected to a suction port (not shown). By drawing air from the suction port, each of the plurality of suction blocks 36 can adsorb and hold the surface of the solar cell 60 coated with adhesive 70. However, each of the plurality of suction blocks 36 only adsorbs and holds the portion of the surface of the solar cell 60 coated with adhesive 70 that does not have adhesive 70 applied to it.

[0034] A rotating shaft 35 is mounted on the lifting shaft 37 so as to be rotatable around the central axis of the rotating shaft 35. The lifting shaft 37 moves the rotating shaft 35 along the Z direction. The lifting shaft 37 has, for example, a lifting motor with a ball screw. A drive mechanism 38 is connected to the rotating shaft 35 and rotates the rotating shaft 35 around its central axis. The drive mechanism 38 has, for example, a motor.

[0035] <Configuration of the transport mechanism 40> Figure 8 is a side view of the transport mechanism 40. As shown in Figure 8, the transport mechanism 40 includes a drive shaft 41, a drive shaft 42, a drive shaft 43, a drive shaft 44, a head 45, a plurality of suction blocks 46, and an imaging device 47.

[0036] The drive shaft 42 is attached to the drive shaft 41. The drive shaft 41 moves the drive shaft 42 along the X direction. The drive shaft 43 is attached to the drive shaft 42. The drive shaft 42 moves the drive shaft 43 along the Y direction. The drive shaft 44 is attached to the drive shaft 43. The drive shaft 43 moves the drive shaft 44 along the Z direction. The head 45 is attached to the drive shaft 44. The drive shaft 44 rotates the head 45 in the XY plane. Note that the drive shafts 41, 42, 43, and 44 are, for example, made up of linear motion robots.

[0037] Multiple suction blocks 46 are attached to the underside of the head 45. Each of the multiple suction blocks 46 is connected to a suction port (not shown). By drawing air in through the suction port, each of the multiple suction blocks 46 can adsorb and hold the surface of the solar cell 60 that is not coated with adhesive 70. The imaging device 47 is positioned opposite the underside of the head 45, with a gap between them. The image captured by the imaging device 47 is output to the controller 50.

[0038] <Configuration of Controller 50> The controller 50 generates control signals for the drive mechanism 13c (motor 13ca), drive mechanism 14c (motor 14ca), drive mechanism 15d (motor 15da), drive mechanism 16d (motor 16da), and lifting shaft 17. The controller 50 also generates control signals for the holding mechanism 20, coating mechanism 30, and transport mechanism 40. In other words, the operation of the positioning mechanism 10, holding mechanism 20, coating mechanism 30, and transport mechanism 40 is determined according to the program stored in the controller 50. The controller 50 may store different programs for the direction in which the solar cells 60 are placed, the size of the solar cells 60, the mass of the solar cells 60, and the material of the solar cells 60.

[0039] (Method for manufacturing solar panels using manufacturing apparatus 100) The method for manufacturing solar panels using manufacturing apparatus 100 is described below.

[0040] Figure 9 is a process diagram showing a method for manufacturing a solar cell panel using the manufacturing apparatus 100. As shown in Figure 9, the method for manufacturing a solar cell panel includes a solar cell supply step S1, a solar cell positioning step S2, an adhesive application step S3, a solar cell inversion step S4, a solar cell transport step S5, an imaging step S6, a tilt correction step S7, and a solar cell bonding step S8.

[0041] In the solar cell supply process S1, multiple solar cells 60 are supplied to the holding mechanism 20. More specifically, each of the multiple solar cells 60 is supplied onto each of the multiple adsorption blocks 21 and is adsorbed and held by each of the multiple adsorption blocks 21. After the multiple solar cells 60 have been supplied to the holding mechanism 20, the holding mechanism 20 is moved below the positioning mechanism 10. Two adjacent solar cells 60 are electrically connected to each other by a wiring member 90 (see Figure 17).

[0042] Figure 10 is a detailed process diagram of the solar cell positioning process S2. As shown in Figure 10, the solar cell positioning process S2 includes a positioning mechanism lowering process S21, a suction release process S22, a first pressing process S23, a second pressing process S24, a third pressing process S25, a suction process S26, a third pressing release process S27, a second pressing release process S28, and a first pressing release process S29.

[0043] Figure 11 is a side view illustrating the positioning mechanism lowering process S21. As shown in Figure 11, in the positioning mechanism lowering process S21, the positioning mechanism 10 is moved downward along the Z direction by operating the lifting shaft 17. In the suction release process S22, the suction and holding by the multiple suction blocks 21 are released by stopping the suction of air from the suction port 22. As a result, the multiple solar cells 60 can move in the XY plane on each of the multiple suction blocks 21.

[0044] FIG. 12 is a plan view for explaining the first pressing step S23. As shown in FIG. 12, in the first pressing step S23, the connecting member 13a is moved along the X direction by operating the drive mechanism 13c. As a result, each of the plurality of support members 13b is pressed against each of the plurality of solar cell units 60, and the intervals between two adjacent solar cell units 60 in the X direction are made uniform. FIG. 13 is a plan view for explaining the second pressing step S24. As shown in FIG. 13, in the second pressing step S24, the base plate 11 is moved along the Y direction by operating the drive mechanism 14c. As a result, each of the plurality of support members 14a is pressed against each of the plurality of solar cell units 60, and the positions of the plurality of solar cell units 60 in the Y direction are made uniform. Note that the order of the first pressing step S23 and the second pressing step S24 may be interchanged.

[0045] FIG. 14 is a first plan view for explaining the third pressing step S25. As shown in FIG. 14, in the third pressing step S25, the connecting member 15a is moved along the X direction by operating the drive mechanism 15d. As a result, each of the plurality of support members 15b rotates about the central axis of the hinge pin 15bb and is pressed against the plurality of solar cell units 60 along a direction different from both the X direction and the Y direction in the XY plane.

[0046] FIG. 15A is an enlarged plan view of the support member 15b in the first state. FIG. 15B is an enlarged plan view of the support member 15b in the second state. FIG. 15C is an enlarged plan view of the support member 15b in the third state. FIG. 15D is an enlarged plan view of the support member 15b in the fourth state. FIG. 15E is an enlarged plan view of the support member 15b in the fifth state. As shown in FIGS. 15A and 15B, as the connecting member 15a moves along the X direction, the rotation angle of the support member 15b about the central axis of the hinge pin 15bb increases. Then, as shown in FIG. 15C, this rotation angle further increases, and when reaching the third state, the support member 15b (cam follower 15bc) contacts the solar cell unit 60.

[0047] FIG. 16A is a schematic graph showing the relationship between the amount of movement of the connecting member 15a in the X direction and the rotation angle of the support member 15b. FIG. 16B is a schematic graph showing the relationship between the amount of movement of the connecting member 15a in the X direction and the force with which the support member 15b presses against the solar cell 60. When the connecting member 15a is moved along the X direction from the third state, the fourth state is reached, and when the connecting member 15a is further moved along the X direction from the fourth state, the fifth state is reached. As shown in FIGS. 15D, 15E, and 16A, since the support member 15b contacts the solar cell 60 in the third state, the rotation angle of the support member 15b does not increase even when reaching the fourth state or the fifth state from the third state.

[0048] However, as shown in FIG. 16B, when reaching from the third state to the fourth state, the elongation of the elastic member 15c increases, and thus, due to the elastic force of the elastic member 15c, a force with which the support member 15b presses against the solar cell 60 is generated. When reaching from the fourth state to the fifth state, the elongation of the elastic member 15c further increases, and thus, the force with which the support member 15b presses against the solar cell 60 further increases. Based on the program stored in the controller 50, the moving speed of the connecting member 15a from the first state to the third state may be controlled to be greater than the moving speed of the connecting member 15a from the third state to the fourth state and the moving speed of the connecting member 15a from the fourth state to the fifth state. Also, based on the program stored in the controller 50, by controlling the position of the connecting member 15a, the force with which the support member 15b presses against the solar cell 60 and its acceleration may be adjusted.

[0049] Figure 17 is an example of a plan view showing a configuration in which multiple solar cells 60 are arranged on a panel member 80. As shown in Figure 17, the multiple solar cells 60 are arranged on the panel member 80 in, for example, multiple rows. These rows are referred to as the first row, the second row, and the third row. The second row is located between the first row and the third row. Each of the multiple solar cells 60 (solar cell 60B) belonging to the second row is arranged symmetrically with respect to each of the multiple solar cells 60 (solar cell 60A) belonging to the first row and each of the multiple solar cells 60 (solar cell 60C) belonging to the third row.

[0050] The spacing between two adjacent solar cells 60A (solar cells 60C) in the X direction and the positions of multiple solar cells 60A (solar cells 60C) in the Y direction can be aligned using multiple support members 13b, multiple support members 14a, and multiple support members 15b. Figure 19 is a second plan view illustrating the third pressing step S25. As shown in Figure 19, the spacing between two adjacent solar cells 60B in the X direction and the positions of multiple solar cells 60B in the Y direction can be aligned using multiple support members 13b, multiple support members 14b, and multiple support members 16b.

[0051] In the adsorption step S26, suction from the suction port 22 is resumed, causing each of the multiple adsorption blocks 21 to again adsorb and hold the multiple solar cells 60. In the third pressing release step S27, the connecting member 15a (connecting member 16a) is moved in the opposite direction to that of the third pressing step S25, thereby releasing the support member 15b from pressing against the solar cells 60.

[0052] Figure 18A is an enlarged plan view of a modified example of the connecting member 15a in the first state. Figure 18B is an enlarged plan view of a modified example of the connecting member 15a in the second state. Figure 18C is an enlarged plan view of a modified example of the connecting member 15a in the third state. Figure 18D is an enlarged plan view of a modified example of the connecting member 15a in the fourth state. Figure 18E is an enlarged plan view of a modified example of the connecting member 15a in the fifth state. As shown in Figures 18A to 18E, the connecting member 15a may have a shape that contacts the connecting member 15ba (the second portion of the connecting member 15ba) in the first state.

[0053] As described above, in the third pressing release step S27, the connecting member 15a is moved in the opposite direction to the third pressing step S25, so that the rotational state of the connecting member 15ba returns to the first state, sequentially passing through the fifth state, fourth state, third state and second state. If the connecting member 15a has a shape that contacts the connecting member 15ba in the first state, even if the elastic force of the elastic member 15c in the contracting direction is weak, the driving force of the drive mechanism 15d is transmitted to the connecting member 15ba by the contact between the connecting member 15a and the connecting member 15ba, making it easier for the rotational state of the connecting member 15ba to return to the first state. Note that if the positioning mechanism 10 is raised before the rotational state of the connecting member 15ba has completely returned to the first state, the cam follower 15bc may come into contact with the solar cell 60 and be damaged.

[0054] In the second release step S28, the base plate 11 is moved in the opposite direction to the second release step S24, thereby releasing the support member 14a (support member 14b) from contact with the solar cell 60. In the first release step S29, the connecting member 13a is moved in the opposite direction to the first release step S23, thereby releasing the support member 13b from contact with the solar cell 60. After the completion of the first release step S29, the lifting shaft 17 is operated to move the positioning mechanism 10 upward along the Z direction and retract it. After the positioning mechanism 10 is retracted, the holding mechanism 20 is moved below the coating mechanism 30. The order of the third release step S27, the second release step S28, and the first release step S29 may be reversed. However, since the elastic force of the elastic member 15c continues to be applied to the solar cell 60 after the third pressing step S25 is performed, it is preferable that the third pressing release step S27 is performed before the second pressing release step S28 and the first pressing release step S29.

[0055] Figure 20 is a side view illustrating the adhesive application process S3. Figure 21 is a plan view illustrating the adhesive application process S3. As shown in Figures 20 and 21, in the adhesive application process S3, the drive shafts 31, 32, and 33 are operated, causing the dispenser 34 to move in the X, Y, and Z directions while the adhesive 70 is applied to the solar cell 60. Figure 22 is a first side view illustrating the solar cell inversion process S4. As shown in Figure 22, in the solar cell inversion process S4, firstly, the lifting shaft 37 is operated to move the rotation shaft 35 downward along the Z direction, and the surface of the solar cell 60 coated with adhesive 70 is adsorbed by the adsorption block 36.

[0056] Figure 23 is a second side view illustrating the solar cell inversion process S4. As shown in Figure 23, in the solar cell inversion process S4, secondly, after the surface of the solar cell 60 coated with adhesive 70 is adsorbed by the adsorption block 36, the drive mechanism 38 is operated. As a result, the rotation shaft 35 rotates around its central axis, and the surface of the solar cell 60 that is not coated with adhesive 70 faces upward in the Z direction.

[0057] Figure 24 is a side view illustrating the solar cell transport process S5. As shown in Figure 24, in the solar cell transport process S5, the head 45 is moved by operating the drive shafts 41, 42, and 43 so that each of the multiple solar cells 60 comes into contact with each of the multiple suction blocks 46, and each of the multiple suction blocks 46 adsorbs and holds the surface of each of the multiple solar cells 60 that is not coated with adhesive 70. In the imaging process S6, the imaging device 47 captures the holding state of the multiple solar cells 60. Note that in the imaging process S6, it is sufficient for the entirety of the multiple solar cells 60 to be included in a single image, and it is not necessary to capture each of the multiple solar cells 60 individually. In the tilt correction process S7, the tilt of the multiple solar cells 60 in the XY plane is corrected by operating the drive shaft 44 based on the image captured by the imaging device 47.

[0058] After the tilt of the multiple solar cells 60 is corrected, the head 45 is transported to the top of the panel member 80 by operating the drive shafts 41, 42, and 43. In the solar cell bonding process S8, the head 45 is moved downward in the Z direction by operating the drive shaft 43, bringing the adhesive-coated surface of each of the multiple solar cells 60 into contact with the panel member 80. As a result, each of the multiple solar cells 60 is bonded to the panel member 80. By repeating the processes from the solar cell supply process S1 to the solar cell bonding process S8, multiple solar cells 60 are mounted on the panel member 80 in multiple rows, and a solar panel is manufactured.

[0059] (Effects of the manufacturing apparatus 100) In the manufacturing apparatus 100, multiple solar cells 60 are positioned simultaneously. Therefore, the manufacturing time of the solar panel is shortened compared to when the solar cells 60 are positioned one by one. If the solar cells 60 are rotating in the XY plane at the start of the solar cell positioning process S2, complete positioning may not be possible by contact between the support members 13b and 14a and the solar cells 60 alone. In the manufacturing apparatus 100, the support member 15b is pressed against the solar cells 60 in a direction different from both the X and Y directions, thereby enabling more reliable positioning of the solar cells 60.

[0060] In the manufacturing apparatus 100, the positioning mechanism 10 positions the multiple solar cells 60, and the adhesive 70 is applied to the solar cells 60 and the solar cells 60 are bonded to the panel member 80 while the relative positions of the multiple solar cells 60 after positioning are maintained. Therefore, it is not necessary to check the position of the solar cells 60 before each process.

[0061] In the manufacturing apparatus 100, the cam followers of support members 13b, 14a, and 15b are pressed against the solar cell 60. As a result, the contact area between each of the support members 13b, 14a, and 15b and the solar cell 60 is small, which improves positioning accuracy. Also, since each of the support members 13b, 14a, and 15b contacts the solar cell 60 at the cam follower, the movement of the solar cell 60 in the direction in which the cam follower and the solar cell 60 are in contact is not easily hindered. In the manufacturing apparatus 100, since support member 15b is pressed against the solar cell 60 by the elastic force of elastic member 15c, variations in the size of the solar cell 60 can be absorbed, and consequently, damage to the solar cell 60 can be suppressed.

[0062] In the manufacturing apparatus 100, the controller 50 has different programs for the direction in which the solar cells 60 are arranged, the size of the solar cells 60, the mass of the solar cells 60, and the material of the solar cells 60. Therefore, even if the arrangement direction, size, mass, material, etc. of the solar cells 60 change, the system can be adapted by changing the program without having to change the settings of each mechanism, thus shortening the manufacturing time of the solar panels.

[0063] In the above example, the workpiece is described as a solar cell 60, but the workpieces that can be targeted by the positioning mechanism 10 and the positioning method using the positioning mechanism 10 are not limited to solar cells. The positioning mechanism 10 and the positioning method using the positioning mechanism 10 can be applied when positioning various multiple workpieces.

[0064] Embodiment 2. The solar panel manufacturing apparatus according to Embodiment 2 will be referred to as manufacturing apparatus 200. Here, we will mainly explain the differences from manufacturing apparatus 100, and will avoid repeating redundant explanations.

[0065] Figure 25 is a plan view of the positioning mechanism 10 in the manufacturing apparatus 200. Figure 26 is a cross-sectional view taken from XXVI-XXVI. As shown in Figures 25 and 26, the positioning mechanism 10 in the manufacturing apparatus 200 has a connecting member 18a and a straightening section 18b. The connecting member 18a is attached to the connecting member 13a. The connecting member 18a extends, for example, in the Y direction. The straightening section 18b is attached to the connecting member 18a. In the illustrated example, there are two straightening sections 18b attached to one connecting member 18a, and the two straightening sections 18b are located at both ends of the connecting member 18a in the Y direction. The straightening section 18b has a cylindrical member 18ba, an elastic member 18bb, and a support member 18bc.

[0066] The cylindrical member 18ba is attached to the connecting member 13a and extends downward in the Z direction. The elastic member 18bb ​​is located inside the cylindrical member 13ba and extends in the Z direction. One end of the elastic member 18bb ​​is attached to the connecting member 13a. The other end of the elastic member 18bb ​​is connected to the support member 18bc. The elastic member 18bb ​​generates an elastic force such that when it is compressed to reduce the distance between its ends, the distance between its ends increases. The support member 18bc is made of a material with low friction, for example. The support member 18bc has a shape with low friction, such as a sphere. The support member 18bc may be rotatable around a rotation axis along the X or Y direction. The support member 18bc is movable in the Z direction along the inner circumferential surface of the cylindrical member 18ba. The connecting member 18a and the straightening portion 18b are located above the solar cell 60 which is placed on the adsorption block 21.

[0067] The solar cells 60 placed on the suction block 21 are thin and may warp during the manufacturing process. A solar cell 60 that has warped will be referred to as solar cell 60D. Figure 27A is the first explanatory diagram illustrating the operation of the manufacturing apparatus 200. When the lifting shaft 17 is driven, that is, when the positioning mechanism lowering process S21 is performed, the base plate 11 descends downward in the Z direction, as shown in Figure 27A. As a result, the support member 18bc comes into contact with the solar cell 60D. When the support member 18bc comes into contact with the solar cell 60D, the elastic member 18bb ​​contracts, and an elastic force from the elastic member 18bb ​​is applied to the solar cell 60D through the support member 18bc. As a result, the solar cell 60D deforms to conform to the suction block 21, and the warping of the solar cell 60D is corrected.

[0068] In the manufacturing apparatus 200, the solar cells 60 are positioned in the X and Y directions while the support member 18bc is in contact with the solar cells 60. Figure 27B is a second explanatory diagram illustrating the operation of the manufacturing apparatus 200. As shown in Figure 27B, for example, in the second pressing step S24, the drive mechanism 14c operates while the support member 18bc is in contact, moving the base plate 11 in the Y direction. As a result, each of the multiple support members 14a is pressed against the multiple solar cells 60, including the solar cells 60D, and the positions of the multiple solar cells 60 in the Y direction are aligned. Because the support member 18bc is made of a low-friction material, has a low-friction structure, or is rotatable, the contact of the support member 18bc with the solar cells 60D does not interfere with the positioning in the X and Y directions (first pressing step S23, second pressing step S24).

[0069] After the solar cell 60 is positioned, the adsorption process S26 is performed. If the solar cell 60D remains warped, positioning and re-adsorption by the adsorption block 21 after positioning will be difficult. The manufacturing apparatus 200 has a straightening section 18b, which allows for straightening of the warp of the solar cell 60 without hindering the positioning of the solar cell 60, and allows the process after re-adsorption by the adsorption block 21 (for example, the adhesive application process S3) to be performed on the solar cell whose warp has been straightened.

[0070] In the above description, an example was given in which the straightening portion 18b is attached to the connecting member 13a via the connecting member 18a. However, it is not necessary for it to be attached to the connecting member 13a via the connecting member 18a, as long as the warping of the solar cell 60D can be eliminated. Also, although a spherical shape was shown as an example of the shape of the support member 18bc, it may have an angular shape as long as friction between it and the solar cell 60D can be reduced. Furthermore, although a material with low friction was given as an example of the material of the support member 18bc, the material of the support member 18bc is not particularly limited as long as the warping of the solar cell 60D can be corrected. In the illustrated example, the solar cell 60D is curved downwards, but the solar cell 60D may also be curved upwards, and the number of straightening portions 18b is not particularly limited.

[0071] The embodiments disclosed herein should be considered in all respects to be illustrative and not restrictive. The scope of this application is indicated by the claims and not by the foregoing description, and all modifications within the meaning and scope equivalent to the claims are intended to be included.

[0072] 10 Positioning mechanism, 11 Base plate, 11a First surface, 11b Second surface, 11c Opening, 12a Linear guide, 12b Linear guide, 13a Connecting member, 13b Support member, 13ba Connecting member, 13bb Cam follower, 13c Drive mechanism, 13ca Motor, 13cb Ball screw, 14a, 14b Support members, 14c Drive mechanism, 14ca Motor, 14cb Ball screw, 15a Connecting member, 15b Support member, 15c Elastic member, 15ba Connecting member, 15bb Hinge pin, 15bc Cam follower, 15d Drive mechanism, 15d Drive mechanism, 15da Motor, 15db Ball screw, 16a Connecting member, 16b Support member, 16c Elastic member, 16ba Connecting member, 16bb 16bc Hinge pin, 16d Cam follower, 16da Motor, 16db Ball screw, 17 Lifting shaft, 18a Connecting member, 18b Straightening part, 18ba Cylindrical member, 18bb ​​Elastic member, 18bc Support member, 20 Holding mechanism, 21 Suction block, 22 Suction port, 30 Coating mechanism, 31 Drive shaft, 32 Drive shaft, 33 Drive shaft, 34 Dispenser, 35 Rotating shaft, 36 Suction block, 37 Lifting shaft, 38 Drive mechanism, 40 Transport mechanism, 41 Drive shaft, 42 Drive shaft, 43 Drive shaft, 44 Drive shaft, 45 Head, 46 Suction block, 47 Imaging device, 50 Controller, 60 Solar cell, 60A, 60B, 60C Solar cell, 70 Adhesive, 80 Panel member, 90 Wiring material, 100 manufacturing equipment, 200 manufacturing equipment, S1 solar cell supply process, S2 solar cell positioning process, S3 adhesive application process, S4 solar cell inversion process, S5 solar cell transport process, S6 imaging process, S7 tilt correction process, S8 solar cell bonding process, S21 positioning mechanism lowering process, S22 suction release process, S23 first pressing process, S24 second pressing process, S25 third pressing process, S26 suction process, S27 third pressing release process, S28 second pressing release process, S29 first pressing release process.

Claims

1. A solar panel manufacturing apparatus comprising a positioning mechanism for positioning a plurality of solar cells, wherein the positioning mechanism comprises a base plate, a first connecting member, a plurality of first support members, a plurality of second support members, a first drive mechanism, and a second drive mechanism, wherein the first connecting member extends along a first direction, the plurality of first support members are connected to the first connecting member so as to be spaced apart along the first direction, the first drive mechanism is connected to the first connecting member and moves the first connecting member along the first direction to press each of the plurality of first support members against each of the plurality of solar cells, the plurality of second support members are attached to the base plate so as to be spaced apart along the first direction, and the second drive mechanism is connected to the base plate and moves the base plate along a second direction perpendicular to the first direction to press each of the plurality of second support members against each of the plurality of solar cells.

2. The solar panel manufacturing apparatus according to claim 1, wherein each of the first and second directions is perpendicular to the vertical direction.

3. A solar panel manufacturing apparatus according to claim 1 or 2, wherein the first drive mechanism moves the first connecting member along the first direction to bring each of the plurality of first support members into contact with each of the plurality of solar cells, thereby positioning each of the plurality of solar cells in the first direction, and the second drive mechanism moves the base plate along the second direction to bring each of the plurality of second support members into contact with each of the plurality of solar cells, thereby positioning each of the plurality of solar cells in the second direction.

4. The solar panel manufacturing apparatus according to any one of claims 1 to 3, wherein the positioning mechanism further comprises a plurality of third support members, the plurality of third support members are spaced apart along the first direction, the plurality of third support members are positioned on the opposite side of the plurality of second support members in the second direction, and each of the plurality of third support members supports each of the plurality of solar cells from a third direction different from both the first and second directions.

5. The solar panel manufacturing apparatus according to claim 4, wherein the positioning mechanism further comprises a second connecting member, a plurality of elastic members, and a third drive mechanism, each of the plurality of elastic members connecting each of the plurality of third support members to the second connecting member, and the third drive mechanism moves the second connecting member along the first direction to press each of the plurality of third support members against each of the plurality of solar cells along the third direction.

6. The solar panel manufacturing apparatus according to any one of claims 1 to 5, further comprising a controller, wherein the controller is configured to change the operation of the positioning mechanism.

7. A solar panel manufacturing apparatus according to any one of claims 1 to 6, further comprising a coating mechanism for applying adhesive to each of the plurality of solar cells positioned by the positioning mechanism.

8. The solar panel manufacturing apparatus according to claim 7, further comprising a transport mechanism for transporting the plurality of solar cells to which the adhesive has been applied by the coating mechanism so that the plurality of solar cells are adhered to a panel member.

9. A solar panel manufacturing apparatus according to any one of claims 1 to 8, further comprising a straightening section for pressing the warped solar cells.

10. The apparatus for manufacturing a solar panel according to claim 9, wherein the straightening section comprises a straightening support member for pressing the warped solar cell and a straightening elastic member connected to the straightening support member, the straightening elastic member contracts when the straightening support member comes into contact with the warped solar cell, thereby generating an elastic force that presses the warped solar cell.

11. A method for manufacturing a solar panel having a plurality of solar cells, comprising a step of positioning the plurality of solar cells, wherein the step of positioning the plurality of solar cells comprises a first pressing step of supporting each of the plurality of solar cells and aligning the positions of each of the plurality of solar cells in a first direction, and a second pressing step of supporting each of the plurality of solar cells and aligning the positions of each of the plurality of solar cells in a second direction perpendicular to the first direction.

12. The method for manufacturing a solar panel according to claim 11, wherein the step of positioning the plurality of solar cells further comprises a third pressing step of supporting each of the plurality of solar cells from a third direction different from both the first and second directions.

13. A method for manufacturing a solar panel according to claim 11 or claim 12, further comprising a coating step of applying an adhesive to each of the positioned plurality of solar cells.

14. The method for manufacturing a solar panel according to claim 13, further comprising a transport step of transporting the plurality of solar cells to which the adhesive has been applied so that the plurality of solar cells are adhered to a panel member.

15. A method for manufacturing a solar panel according to any one of claims 11 to 14, further comprising a straightening step of pressing the warped solar cells.

16. A positioning mechanism for positioning multiple workpieces, comprising: a base plate; a first connecting member extending in a first direction; a plurality of first support members connected to the first connecting member so as to be spaced apart along the first direction; a plurality of second support members attached to the base plate so as to be spaced apart along the first direction; a first drive mechanism connected to the first connecting member and moving the first connecting member along the first direction to press each of the plurality of first support members against each of the plurality of workpieces; and a second drive mechanism connected to the base plate and moving the base plate along a second direction perpendicular to the first direction to press each of the plurality of second support members against each of the plurality of workpieces.

17. A positioning method for positioning multiple workpieces, comprising: a first pressing step of supporting each of the multiple workpieces and aligning the positions of each of the multiple workpieces in a first direction; and a second pressing step of supporting each of the multiple workpieces and aligning the positions of each of the multiple workpieces in a second direction perpendicular to the first direction.

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