Busbar Stitch Welding Layout With Three-Support Sequential Transfer
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Solution Overview
Problem
Existing busbar welding devices require multiple supporting mechanisms and preparation mechanisms for each busbar, leading to increased manufacturing costs and footprint due to the need for ten busbar supporting mechanisms and simultaneous preparation of ten busbars in solar cell module manufacturing.
Innovation Solution
A busbar welding device with reduced supporting mechanisms and preparation mechanisms, utilizing a first and second busbar preparation mechanism to prepare different types of busbars, and a busbar transfer mechanism to sequentially support and weld busbars, reducing the number of supporting mechanisms needed and allowing for efficient preparation of L-shaped and U-shaped busbars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If all busbars are welded simultaneously after complete layup, then welding completeness is achieved, but the number of supporting mechanisms increases to ten
Solution Approach 1:
The welding process is divided into multiple stages: front-end straight busbar welding, central portion bent busbar welding, and rear-end straight busbar welding. This segmentation allows different types of busbars to be welded separately at different locations, reducing the number of supporting mechanisms needed at any one time from ten to three.
Solution Approach 2:
Busbars are prepared in advance according to their specific requirements (straight or bent, front-end or rear-end) and positioned at designated locations before welding. The busbar preparation mechanism prepares busbars beforehand, and the busbar transfer mechanism transports them to the appropriate supporting mechanisms, enabling staged welding without requiring all busbars to be supported simultaneously.
2Reliability
If ten busbars are prepared simultaneously, then all welding requirements are met, but manufacturing cost increases
Solution Approach 1:
The busbar preparation process is segmented by type and location: front-end straight busbars, rear-end straight busbars, and central portion bent busbars are prepared separately. The busbar preparation mechanism can prepare different types of busbars in sequence or parallel based on demand, reducing the number of busbars that need to be prepared simultaneously from ten to a smaller number, thereby lowering manufacturing costs.
Solution Approach 2:
The busbar preparation mechanism is designed with multi-functionality to handle different types of busbars (straight and bent, front-end and rear-end) using the same or similar preparation processes. This universality allows the system to prepare various busbar types efficiently without requiring separate dedicated mechanisms for each type, reducing overall system complexity and cost.
3Reliability
If ten busbars are prepared simultaneously, then all welding needs are satisfied, but device footprint increases
Solution Approach 1:
The welding operation is segmented into multiple stations located at different positions along the cell string assembly: front-end welding station, central portion welding station, and rear-end welding station. Each station has its own supporting mechanism(s), allowing busbars to be prepared and welded in sequence rather than all at one location. This spatial segmentation reduces the footprint required for busbar preparation and supporting mechanisms.
Solution Approach 2:
The busbar transfer mechanism transports busbars along the length of the cell string assembly (first horizontal direction) to different welding stations, utilizing the longitudinal dimension of the assembly. This allows the system to distribute busbar preparation and welding activities along the length of the module rather than concentrating them in a single area, effectively reducing the footprint of the welding device.
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
The device achieves automatic welding of busbars with reduced costs and footprint by requiring only three supporting mechanisms, enhancing production efficiency and reducing waiting times for bent busbar preparation.
Implementation Method 1
a welding mechanism (7), wherein the first busbar preparation mechanism (1) is configured to prepare front-end straight busbars, L-shaped bent busbars, and U-shaped bent busbars
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
Disclosed are a busbar welding device (10), a layup and stitch-welding apparatus, and a stitch-welding method. The busbar welding device (10) is configured to weld busbars to component units in a cell string assembly, each component unit comprising two cell strings, and a plurality of component units forming the cell string assembly. The busbar welding device (10) comprises a first busbar preparation mechanism (1), a second busbar preparation mechanism (2), a busbar transfer mechanism (3), a first busbar supporting mechanism (4), a second busbar supporting mechanism (5), a third busbar supporting mechanism (6), a stitch-welding gripper (8), and a welding mechanism (7).