Inductor Insert Layout for Flexible PV Interconnection Soldering
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Solution Overview
Problem
Existing soldering devices for photovoltaic panels require reprogramming or terminal replacement when panel formats change, leading to inefficient production and downtime.
Innovation Solution
A device with an inductor having parallel branches and a longitudinally arranged insert, which heats the header ribbon uniformly regardless of bus bar spacing, using a magnetic field and cooling mechanism to ensure consistent soldering across different panel formats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional welding devices are used for soldering photovoltaic module interconnections, then the basic soldering function is achieved, but the device complexity increases and manufacturing precision deteriorates due to lack of positioning accuracy
Solution Approach 1:
The device is divided into distinct functional modules: a positioning system with guide rails and positionable clamps for precise location, a welding gun assembly for soldering, and a control system. This segmentation allows each module to be optimized independently while maintaining overall system precision without excessive complexity.
Solution Approach 2:
Positionable clamps serve as intermediaries between the positioning system and the photovoltaic module interconnections. These clamps provide precise positioning and stable support during the welding process, ensuring manufacturing precision while keeping the overall device structure manageable.
2Productivity
If manual positioning methods are used for photovoltaic module interconnections, then device complexity is reduced, but productivity decreases due to time-consuming alignment processes
Solution Approach 1:
The positioning system performs preliminary positioning actions before the actual welding process. Guide rails and positionable clamps pre-establish the correct positions of photovoltaic module interconnections, eliminating time-consuming manual alignment during welding and thus improving productivity.
Solution Approach 2:
The system replaces manual mechanical positioning with an automated positioning mechanism featuring guide rails and motorized or pneumatic positionable clamps. This substitution reduces the time required for alignment while maintaining device complexity at an acceptable level through standardized components.
3Reliability
If stable support is not provided for photovoltaic module interconnections, then device complexity is reduced, but welding quality deteriorates due to movement and misalignment
Solution Approach 1:
Positionable clamps act as intermediaries that provide stable support for photovoltaic module interconnections during welding. These clamps securely hold the interconnections in place, preventing movement and misalignment, thereby ensuring welding quality without requiring an overly complex support structure.
Solution Approach 2:
The support structure provides localized stability exactly where needed—at the interconnection points during welding—rather than requiring comprehensive support throughout the entire system. This localized approach maintains welding quality while minimizing overall device complexity.
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 flexible soldering across various panel formats without terminal replacement, enhancing productivity and reducing downtime.
Implementation Method 1
an inductor (50) arranged to generate an induction field across the solder material (40)
Implementation Method 2
The inductor (50) is arranged to generate an induction field across the solder material (40) to be applied to the first and second interconnections (31, 32)
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
The present invention concerns a device (10) for soldering the interconnections of photovoltaic panels (1).Said device (10) comprises: an inductor (11), which in turn comprises a filament (12), which substantially develops so as to form two parallel branches (13a, 13b): a first branch (13a) and a second branch (13b), and an insert (14), which has a longitudinal development, which is at least partly surrounded longitudinally by said filament (12) and is interposed between said two branches (13a, 13b).