Photovoltaic Module Film Alignment Using Multi-Module Edge Positioning
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Solution Overview
Problem
Existing photovoltaic module assembly processes face challenges in aligning the film with the glass plate accurately, as the film often becomes uneven or deviated during transportation, leading to issues in subsequent processes like lamination and edge sealing.
Innovation Solution
An automatic alignment device comprising a component conveyor line, alignment mechanism, leveling mechanism, pressing mechanism, camera group, film lifting mechanism, and welding mechanism, which aligns and fixes the film edges with the glass plate edges, ensuring precise positioning for subsequent battery cell layout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If only a leveling mechanism is used to flatten the film, then the film unevenness is solved, but the film deviation from glass plate edges remains
Solution Approach 1:
The alignment mechanism is divided into multiple independent alignment modules (first, second, third, and fourth alignment modules) positioned at different locations. Each module independently adjusts and aligns specific edges of the film with the glass plate, enabling precise edge alignment while maintaining film flatness through the combined action of all modules.
Solution Approach 2:
The patent introduces an intermediary alignment mechanism between the leveling mechanism and the final positioning. This alignment mechanism uses alignment wheels and adjustment components to mediate the relationship between the film and glass plate, enabling precise edge alignment that goes beyond simple flatness correction.
2Device complexity
If manual alignment methods are used, then equipment complexity is reduced, but alignment accuracy and efficiency deteriorate
Solution Approach 1:
The alignment mechanism is designed to automatically detect and adjust film position without manual intervention. The multiple alignment modules work together to self-align the film edges with the glass plate edges, achieving high precision through automated mechanical adjustment rather than manual operation.
Solution Approach 2:
The patent replaces manual mechanical alignment operations with an automated mechanical alignment system consisting of multiple alignment modules. This substitution of manual labor with automated mechanical components achieves both high precision and improved efficiency while maintaining reasonable equipment complexity.
3Productivity
If film alignment is not corrected, then production speed is maintained, but subsequent process quality deteriorates
Solution Approach 1:
The alignment mechanism performs preliminary alignment correction before the film is used in subsequent battery cell layout processes. By pre-aligning the film edges with the glass plate edges using the multiple alignment modules, the system ensures that subsequent processes proceed with high quality while maintaining production speed through automated correction.
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 solution effectively smooths and aligns the film on the glass plate, providing a reliable position basis for subsequent processes, preventing uneven adhesive overflow and eliminating the need for cleaning and edge trimming.
Implementation Method 1
The welding mechanism is configured to fix the film to the surface of the glass plate at a set position by welding.
Data Source
AI summary
An automatic alignment device includes a component conveyor line, an alignment mechanism for aligning four sides of components on the component conveyor line, a camera group located above the component conveyor line for taking pictures of at least three right-angled edge areas of the component, a leveling mechanism located above the component conveyor line for leveling the film on the glass plate, a pressing mechanism located above the component conveyor line and configured to press a set position of the film in assisting the operation of the leveling mechanism, a film lifting mechanism located above the component conveyor line and configured to move the flattened film upwards, and a welding mechanism arranged above the component conveyor line to fix at a set position the film on the glass module.