Automated PV Module Sorting and Packing System
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Solution Overview
Problem
The existing technologies fail to provide an efficient and cost-effective method for fully automatically selecting and packing photovoltaic modules of varying quality levels produced in large batches, which is essential for reducing production costs and ensuring reliable handling and integration of impact-sensitive glass panes in clean room conditions.
Innovation Solution
A device and method that includes a quality testing station for classifying photovoltaic modules based on performance parameters, followed by automatic assembly and packaging using module carriers, lifting sucker devices, and a storage system for sorting and packaging modules according to their performance classes, utilizing sensors and barcode/RIDF systems for data linkage and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If photovoltaic modules are produced in large batches to reduce costs, then production cost decreases, but quality uniformity deteriorates
Solution Approach 1:
The patent applies preliminary action by performing quality classification of photovoltaic modules immediately after production before packing. The system measures electrical parameters (open-circuit voltage, short-circuit current) and assigns quality classes to each module in advance, ensuring that modules of the same quality are grouped together. This preliminary classification resolves the quality uniformity issue while maintaining large-batch production efficiency.
2Adaptability or versatility
If manual selection and packing methods are used, then flexibility in handling different quality levels is maintained, but automation level and productivity decrease
Solution Approach 1:
The system applies self-service by using sensors and measurement devices that automatically detect module quality parameters and trigger the appropriate packing action. The control unit autonomously decides which packing station should receive each module based on its measured quality class, eliminating the need for manual inspection and sorting while maintaining full adaptability to different quality levels.
Solution Approach 2:
The patent implements feedback by continuously measuring electrical parameters of each module and using this information to control the packing process. The control unit receives real-time data about module quality and automatically routes modules to appropriate packing stations, creating a closed-loop system that maintains both automation and adaptability.
3Reliability
If impact-sensitive glass panes are handled in clean room conditions, then product quality and reliability are maintained, but handling complexity and operational difficulty increase
Solution Approach 1:
The patent replaces manual mechanical handling with an automated lifting and positioning system that uses suction cups or clamps to grasp and move glass panes. This mechanical substitution eliminates the need for operators to directly handle fragile glass components, reducing contamination risk in clean room conditions while simplifying the operational process.
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 the reliable, automatic, and cost-effective selection and packing of photovoltaic modules by ensuring accurate classification, handling, and packaging, reducing production costs and improving handling efficiency while maintaining quality standards.
Implementation Method 1
a lifting sucker device (4) for holding the photovoltaic modules (6) in a vertical orientation
Data Source
AI summary
The disclosure relates to a method and to a device for fully automatically selecting and packing photovoltaic solar modules, for example, produced in mass production. The device may include the following characteristics: a production line, b) a quality checking device having devices for mechanical final testing and electrical final testing, c) an assembly device for module carriers, d) a device for distributing and stacking the solar modules in the horizontal and vertical direction according to particular selection criteria at acceptance locations corresponding to said selection criteria, e) devices for placing strips as spacers between stacked modules, wherein different types of strips can be taken from a magazine, f) devices for collating packages of a plurality of solar modules at each acceptance location, wherein aid devices each comprise a film wrapper, a protective cap applicator, and a strapping device.