90-Degree Turnover Method for Photovoltaic Assemblies
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Solution Overview
Problem
Existing methods for 90-degree turnover of photovoltaic assemblies in packaging are inefficient, time-consuming, and prone to stress-induced damage due to the need for manual intervention and the use of prongs that can cause local squeezing and hidden breaks.
Innovation Solution
A high-rhythm and high-precision 90-degree turnover method utilizing a conveyor system with a horizontal transfer module, a turnover module, and a position adjustment mechanism, which enables synchronized and efficient turnover operations, precise alignment, and reduced stress on the assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a prong is used to turn over the stacked assembly on the assembly conveyor line, then the 90-degree turnover can be achieved, but the turnover process becomes time-consuming and inefficient due to the need for sequential operations
Solution Approach 1:
The turnover system is divided into independent segments: the first conveyor line for input, the second conveyor line for turnover, and the horizontal transfer module for transition. This segmentation allows parallel operations where the first conveyor can continuously feed assemblies while the turnover operation occurs on the second line, eliminating sequential waiting time and improving overall productivity.
Solution Approach 2:
The horizontal transfer module acts as an intermediary between the first conveyor line and the second conveyor line. It receives assemblies from the first line, positions them for turnover on the second line, and enables smooth transition without interrupting the continuous flow from the first conveyor, thus maintaining high productivity while ensuring precise turnover.
2Manufacturing precision
If the prong is turned over by 90 degrees on the assembly conveyor line, then the turnover is completed, but partial regions of the stacked assembly are squeezed by great stress causing risk of hidden breaks
Solution Approach 1:
The horizontal transfer module serves as an intermediary that transitions assemblies from the first conveyor line to the second conveyor line in a controlled manner. This intermediary mechanism distributes the turnover stress across the entire assembly structure rather than concentrating it at specific regions, preventing local squeezing and hidden breaks while achieving precise 90-degree turnover.
Solution Approach 2:
The turnover system uses dynamic control through the horizontal transfer module and independently controllable conveyor lines. The assembly is gradually transitioned and positioned during transfer, allowing controlled rotation rather than abrupt 90-degree flipping. This dynamic approach reduces peak stress on the assembly structure while maintaining turnover precision.
3Reliability
If manual intervention and sequential prong operations are used for turnover, then the turnover can be performed, but the overall period is time-consuming and inefficient
Solution Approach 1:
The system maintains continuous useful action through two independently operable conveyor lines. While the second conveyor line performs the turnover operation, the first conveyor line continues to receive and prepare the next assembly for turnover. This eliminates idle time and waiting periods, significantly reducing the turnover cycle time while maintaining reliable turnover through automated control.
Solution Approach 2:
The horizontal transfer module performs preliminary positioning and preparation of assemblies before they reach the turnover point on the second conveyor line. Assemblies are pre-positioned on the first conveyor line and smoothly transferred to the second line, so that when turnover occurs, the assembly is already optimally positioned. This preliminary action eliminates the need for manual intervention and reduces the overall turnover time.
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 method significantly reduces turnover time, improves efficiency, enhances precision, and minimizes the risk of assembly damage by allowing continuous conveyor operation and precise positioning of the assemblies during the turnover process.
Implementation Method 1
a hydraulic cylinder configured to drive the third support to turn over
Implementation Method 2
a third motor fixed on the third support, a prong group which is configured to be driven by the third motor to move left and right
Data Source
AI summary
A high-rhythm and high-precision 90-degree turnover method including: changing materials; turning a prong over and waiting; driving a first drum conveyor line to move leftward to a turnover station; adjusting front and rear positions of the first drum conveyor line as a whole to make a stacked assembly aligned with a center line of the wooden pallet; driving a first drum conveyor line to move leftward to make a left surface of the stacked assembly abut against a surface of the wooden pallet; driving a prong group to move upward to a second height position to support the stacked assembly; and driving a third support to turn over by 90 degrees reversely to make a second drum conveyor line turned over to a horizontal state.