Bivalent Workstation for Shingled String Assembly
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Solution Overview
Problem
Current methods for assembling photovoltaic panels with top-bottom contact cells have limited automation, require intermediate drying of conductive adhesive, and are inflexible, leading to increased production costs and complexity, while methods for back-contact cells do not allow for the assembly of traditional cells with shingled strings without intermediate drying and are not versatile enough for market demands.
Innovation Solution
A bivalent workstation and method that integrates printing and pre-fixing of shingled strings in a continuous cycle without intermediate drying, allowing for the assembly of both traditional top-bottom contact cells and back-contact cells on the same equipment, using a combined station with coordinated handlers and vision systems to form and load shingled strings directly onto a backsheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional assembly methods for photovoltaic panels with top-bottom contact cells are used, then intermediate drying of conductive adhesive is required, but this increases production time and process complexity
Solution Approach 1:
The patent combines the string formation process and panel assembly process into a single integrated workstation. The string formation unit forms shingled strings and transfers them directly to the panel assembly unit, eliminating the need for intermediate drying steps that would otherwise be required between separate formation and assembly operations.
Solution Approach 2:
The string formation unit performs preliminary formation of shingled strings with conductive adhesive applied, and these strings are immediately transferred to the panel assembly unit without requiring intermediate drying. The continuous operation maintains the adhesive in a workable state through rapid transfer.
2Productivity
If dedicated equipment for back-contact cells is used, then assembly of back-contact cells is efficient, but the equipment cannot assemble traditional top-bottom contact cells with shingled strings
Solution Approach 1:
The workstation is designed with universal capabilities to handle both back-contact cells and traditional top-bottom contact cells. The string formation unit can form strings for traditional cells, and the panel assembly unit can assemble both cell types using the same coordinated handler and vacuum belt system.
Solution Approach 2:
The workstation employs dynamic, reconfigurable components including coordinated handlers with adjustable gripping mechanisms and a vacuum belt system that can adapt to different cell types. The system can switch between assembling back-contact cells and traditional cells with shingled strings through programmable control.
3Adaptability or versatility
If manual or semi-automatic assembly methods are used, then flexibility in handling different cell types is maintained, but automation level and production efficiency are limited
Solution Approach 1:
The system employs automated string formation where the string formation unit automatically forms shingled strings with precise adhesive application and cell positioning. The coordinated handler automatically transfers these strings to the panel assembly unit, and the vacuum belt system automatically positions cells during assembly, eliminating manual operations while maintaining flexibility through programmable control.
4Reliability
If separate workstations for string formation and panel assembly are used, then each workstation can be optimized for its specific function, but overall device complexity and space requirements increase
Solution Approach 1:
The patent integrates the string formation unit and panel assembly unit into a single workstation with shared components. The coordinated handler serves both units, the vacuum belt system is共用 for cell positioning in both operations, and the control system manages both functions, reducing overall system complexity while maintaining functional optimization.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces production time and costs, enhances automation, and allows for greater versatility in producing photovoltaic panels with shingled strings, eliminating the need for intermediate drying and enabling faster, more precise assembly of traditional and back-contact cells in a single integrated process.
Implementation Method 1
moving, in a continuous cycle, on a vacuum belt
Implementation Method 2
printing of ECA (conductive adhesive) and progressive superimpositions
Data Source
AI summary
An assembly method and a combined and bivalent workstation for automatically assembling photovoltaic panels, with printing of ECA on cell portions and progressive arrangement with a partial superimposition on the contacts, pre-forming shingled strings in a continuous cycle, which are ready for loading on a backsheet, without dry-curing. The method provides a macro-phase of lay-up entirely made in the station, with simultaneous and coordinated sub-phases: picking of portions with a first handler and control, oriented loading on a vacuum belt, control of positioning on the belt, printing of ECA, control of printing and positioning, progressive superimpositions on a shuttle-tray with bidirectional translation coordinated with a second handler with chocked vacuum, picking of the shingled string with a third handler, control of string alignment, loading and pre-fixing. Vision systems are integrated for the execution of said sub-phases.