Photovoltaic Module Dismantling via Backlight Wire Positioning
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Solution Overview
Problem
Existing methods for disassembling photovoltaic modules using abrasive wires struggle to accurately adjust the feed and cutting speeds due to the inability to account for the position of the wire during cutting, leading to potential degradation of the encapsulation material and inefficiencies.
Innovation Solution
An installation that uses a backlighting device to emit light signals through the photovoltaic module, coupled with optical capture means and a control unit, to determine the position of the abrasive wire and adjust the feed and cutting speeds accordingly, ensuring precise control during the disassembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual dismantling methods are used, then flexibility and adaptability are maintained, but labor intensity is high and processing time is excessive
Solution Approach 1:
The dismantling system is divided into multiple independent modules including heating unit, pressing unit, cutting unit, and separation unit. Each module performs a specific function in the dismantling process, allowing for automated high-speed operation while maintaining manageable system complexity through functional segmentation.
Solution Approach 2:
Multiple dismantling functions (heating, pressing, cutting, separation) are combined into a single integrated automated apparatus that processes photovoltaic modules in one continuous operation, significantly increasing dismantling speed compared to manual methods while keeping the overall system complexity controlled through modular design.
2Productivity
If conventional crushing methods are used, then processing speed is increased, but material recycling value is lost due to excessive fragmentation
Solution Approach 1:
The cutting unit applies localized controlled cutting forces at specific positions on the photovoltaic module rather than universal crushing forces. This allows for precise separation of components while maintaining the structural integrity of recyclable materials like aluminum frames and glass panels, enabling high-speed processing without excessive fragmentation.
Solution Approach 2:
The system changes the physical parameters of the dismantling process by controlling temperature, pressure, and cutting force to achieve clean separations. The heating unit softens adhesive bonds, the pressing unit applies controlled force, and the cutting unit uses precise mechanical separation, all working together to maintain material quality while increasing processing speed.
3Speed
If high force is applied during dismantling, then separation speed is increased, but damage to recyclable components occurs
Solution Approach 1:
The heating unit is activated before the cutting and separation operations to pre-soften the adhesive bonds and make the module more pliable. This preliminary thermal action reduces the force required for subsequent mechanical separation, enabling faster dismantling while preserving the strength and integrity of recyclable components.
Solution Approach 2:
The pressing unit acts as an intermediary between the cutting mechanism and the module components. It applies distributed controlled pressure to stabilize the module during cutting, preventing sudden movements or fractures that could damage recyclable components while maintaining efficient separation speed.
4Loss of time
If complete disassembly is performed manually, then material quality is preserved, but time consumption and labor costs increase significantly
Solution Approach 1:
The automated dismantling apparatus performs the complete disassembly process autonomously through coordinated operation of heating, pressing, cutting, and separation units. The system self-regulates the dismantling sequence and parameters, dramatically reducing dismantling time from manual hours to automated minutes while managing operational complexity through integrated control systems.
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 accurate determination of the abrasive wire's position, allowing for automatic adaptation of its speed based on the encountered materials, thereby enhancing the disassembly efficiency and reducing material degradation.
Implementation Method 1
a heating unit configured to heat the back sheet
Implementation Method 2
a pressing unit configured to press the photovoltaic module
Implementation Method 3
a cutting unit configured to cut the photovoltaic module
Data Source
Figure 1~3
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Figure 5
AI summary
The invention relates to an apparatus for dismantling a photovoltaic module (M), said photovoltaic module (M) comprising photovoltaic cells (20) arranged between a first protective element (3) and a second protective element (1), an encapsulating casing (2) for the photovoltaic cells connecting the first protective element to the second protective element, said apparatus comprising: An abrasive wire (F) controlled to move in a translational direction and in a plane, referred to as the cutting plane, located between the front surface and the rear surface of the photovoltaic module (M) in order to cut the photovoltaic module according to this cutting plane, -and a backlighting device (5) arranged to emit light signals (S_L) through the photovoltaic module (M) with a view to determining the position of the abrasive wire (F) during cutting.