Induction Soldering Head With Longitudinal Insert for Flexible PV Panels
Solution Overview
Problem
Existing devices for soldering photovoltaic panel interconnections are inefficient and require terminal replacement or reprogramming when panel formats change, leading to reduced productivity and increased downtime.
Innovation Solution
A device with a filament forming two parallel branches and an insert made of glass-ceramics, surrounded by the filament, which heats the header ribbon homogeneously across its length, allowing for flexible panel formats without terminal replacement, using a heating head with electrodes and cooling water flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a terminal with a single induction point is used that moves along the header ribbon, then the device can handle different panel formats, but the production method becomes long and uncomfortable with reduced productivity
Solution Approach 1:
The filament is divided into multiple independent induction points (first, second, third, and fourth induction points) arranged in a matrix pattern. This segmentation allows simultaneous soldering at multiple locations along the header ribbon, eliminating the need for sequential movement of a single induction point and thereby increasing productivity while maintaining adaptability to different panel formats through programmable control of each segment.
Solution Approach 2:
Multiple induction points are combined into a single terminal structure that can operate simultaneously at multiple positions. This merging of multiple induction functions into one terminal eliminates the need to replace terminals when changing panel formats, as the combined structure can handle various formats through coordinated operation of its multiple induction points.
2Productivity
If a terminal with multiple induction points is used, then productivity increases, but the terminal must be replaced when panel format changes
Solution Approach 1:
The terminal is designed with multiple induction points that can be programmed to serve different functions depending on the panel format being processed. The same terminal structure can accommodate various panel formats by adjusting the activation and positioning of its multiple induction points, eliminating the need for physical terminal replacement while maintaining high productivity.
Solution Approach 2:
The terminal incorporates programmable control that allows dynamic adjustment of which induction points are active and their positioning, enabling the same terminal to adapt to different panel formats on the fly without physical replacement, while maintaining the high productivity enabled by having multiple induction points available.
3Measurement precision
If a laser source is used for soldering, then precise punctual soldering is achieved, but the production method becomes long and uncomfortable with reduced productivity
Solution Approach 1:
The laser source is divided into multiple independent laser beams corresponding to multiple induction points arranged in a matrix. This segmentation allows simultaneous precise soldering at multiple locations along the header ribbon, maintaining the precision of individual laser soldering while dramatically increasing productivity through parallel operation of multiple laser points.
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
Enables efficient soldering of photovoltaic panel interconnections for any format, increasing productivity by eliminating the need for terminal replacement and ensuring consistent connections regardless of bus bar distance.
Implementation Method 1
an inductor, which in turn comprises a filament... To connect the bus bars to the header ribbons, a soldering is normally carried out between them, melting the tin that covers the header ribbon
Implementation Method 2
numerical control equipment equipped with induction or laser soldering devices, which carry out a punctual soldering by melting the header ribbon
Implementation Method 3
The filament 12 is advantageously made of copper and has a tubular section with a square contour for the flow of cooling water
Data Source
AI summary
The present disclosure concerns a device for soldering the interconnections of photovoltaic panels. The device includes: an inductor, which in turn includes a filament, which substantially develops so as to form two parallel branches: a first branch and a second branch, and an insert, which has a longitudinal development, which is at least partly surrounded longitudinally by said filament and is interposed between said two branches.