Junction Box Removal Mechanism for Damage-Free Solar Module Recycling
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Solution Overview
Problem
The manual removal of junction boxes from solar cell modules during recycling is labor-intensive, inconvenient, and risks damaging the glass cover.
Innovation Solution
A removing device with a seat regulating module, aligning and holding seat module, removing seat, and removing driving module, which enables an automatic removing process for junction boxes from solar cell modules, minimizing the risk of damage to the solar panel unit and glass cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual removal of junction boxes is performed using hand tools, then the process can be carried out with simple equipment, but the labor intensity increases and damage risk to the glass cover worsens
Solution Approach 1:
The patent replaces manual mechanical operations with an automated mechanical system. The removing device uses a driving module to automatically move the removing seat along the back plate, and the removing component automatically contacts and pries the junction box, eliminating the need for manual hand tool operations while reducing labor intensity.
Solution Approach 2:
The removing device is designed to perform the removal operation autonomously once positioned. The removing component automatically contacts the junction box and applies prying force through the driving module's movement, allowing the system to service itself without continuous manual intervention throughout the removal process.
2Device complexity
If manual removal using hand tools is used, then equipment simplicity is maintained, but the risk of damage to the glass cover increases
Solution Approach 1:
The removing component acts as an intermediary between the driving module and the junction box. It is specifically designed to contact only the junction box and not the glass cover, transferring the prying force selectively to the junction box while protecting the glass cover from damage during the removal operation.
Solution Approach 2:
The removing component is designed with specific local properties - its contact surface and geometry are tailored to engage only with the junction box structure. This localized design ensures that force is applied precisely where needed (at the junction box adhesive interface) without affecting surrounding areas like the glass cover.
3Ease of operation
If automatic removal process is implemented, then labor intensity is reduced and damage risk is minimized, but device complexity increases
Solution Approach 1:
The removing device is divided into distinct functional modules: a positioning module to locate the junction box, a removing component to perform the prying action, and a driving module to provide automated movement. This segmentation allows each component to be optimized for its specific function while working together in an automated sequence, reducing the overall complexity compared to a fully integrated system.
Data Source
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AI summary
A removing device (200) for removing a junction box (802) from a solar cell module (800) includes a carriage mechanism (4) and a removing mechanism (5) mounted on a frame mechanism (3). The removing mechanism (5) includes a seat regulating module (52), an aligning and holding seat module (53) and a removing seat (54) which is moved by the seat regulating module (52) toward a back plate of a solar panel unit (801), and a removing driving module (56) which drives movement of the removing seat (54) toward the junction box (802) along the back plate of the solar panel unit (801) so as to move a cutting edge (543) of the removing sear (54) into a juncture between the junction box and the back plate and remove the junction box (802). An automatic removing process is performed, and damage to the solar panel unit (801) is prevented.