Photovoltaic Cell String Welding with Buffered Continuous Heating
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Solution Overview
Problem
Existing photovoltaic cell string welding machines experience unstable temperature fluctuations due to frequent turning on and off of infrared heating sources, leading to inconsistent welding quality and increased maintenance costs with complex structures.
Innovation Solution
A continuous string welding device with independent conveyor sections for step-by-step and continuous motion, incorporating a buffering section to store cells before continuous conveyance to the welding section, ensuring consistent temperature and stable welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the infrared heating source is turned on and off frequently for each welding operation, then the welding process can be completed for individual cells, but the temperature in the welding zone becomes unstable and welding quality fluctuates
Solution Approach 1:
The conveyor system is divided into multiple independent conveying sections (first conveying section, second conveying section, third conveying section) that can operate at different speeds and modes. This segmentation allows the heating section to maintain continuous operation while other sections handle loading and unloading, resolving the contradiction between productivity and temperature stability.
Solution Approach 2:
Cells are pre-positioned and prepared in the first conveying section before entering the heating section. The buffering section stores cells in advance, allowing the heating source to maintain continuous operation without frequent start-stop cycles, thereby maintaining temperature stability while ensuring continuous productivity.
2Manufacturing precision
If the conveyor system operates in a step-by-step manner for positioning, then precise alignment is achieved, but the welding zone experiences temperature fluctuations and the process is less efficient
Solution Approach 1:
The conveyor system dynamically adjusts its operation mode: the first conveying section operates in step-by-step mode for precise positioning, while the second and third conveying sections operate in continuous mode for efficient transport. This dynamic adjustment resolves the contradiction between positioning precision and welding efficiency.
Solution Approach 2:
Different conveying sections perform different functions: positioning vs. transport. This segmentation allows precise step-by-step positioning where needed while maintaining continuous efficient transport in other areas, resolving the contradiction between precision and productivity.
3Adaptability or versatility
If a complex string welding machine structure is used to connect cells in series, then welding functionality is achieved, but processing precision requirements increase and maintenance costs rise
Solution Approach 1:
The conveyor belt system serves multiple functions: it conveys cells, positions them, buffers them, and transports them through the heating zone. This multi-functionality eliminates the need for separate complex mechanisms for each function, reducing overall device complexity while maintaining welding functionality.
Solution Approach 2:
The positioning mechanism, buffering mechanism, and conveying mechanism are merged into a single integrated conveyor system. This consolidation reduces the number of separate components and simplifies the overall machine structure while maintaining all necessary welding functions.
4Use of energy by moving object
If the welding light box is turned on and off frequently, then energy is saved during non-welding periods, but temperature stability is compromised and welding quality becomes inconsistent
Solution Approach 1:
The heating light box operates continuously without interruption, maintaining stable temperature in the welding zone. The conveyor system's segmentation and continuous operation in the heating section ensure that cells are constantly moving through the heating zone, making continuous heating both energy-efficient and quality-consistent.
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 uniform and stable welding quality by maintaining consistent cell heating, reducing maintenance costs, and improving production yield and device uptime.
Implementation Method 1
a welding mode with infrared heating is used, that is, one or more cells to be welded on the same strip enter the welding station in a step-by-step manner, and then, a light source of an infrared light box module is turned on for a certain period of time
Implementation Method 2
a power transmission mechanism including a welding strip positioning section, a buffering section, and a welding section that perform conveying independently from each other in sequence in a conveying direction
Data Source
AI summary
The present disclosure discloses a continuous string welding device for photovoltaic cells and a welding method. The device includes a power transmission mechanism and a welding light box. The power transmission mechanism includes a welding strip positioning section, a buffering section and a welding section that perform conveying independently from each other in sequence in the conveying direction. The buffering section is capable of storing at least one string of cells. The welding light box is located in the welding section. The welding strip positioning section performs step-by-step motion conveying. The welding section performs continuous motion conveying. The buffering section is configured to receive a predetermined number of cells from the welding strip positioning section, connect the predetermined number of cells in series, and then convey the predetermined number of cells connected in series to the welding section.