Photovoltaic Assembly Vertical Turnover with Distance Correction
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Solution Overview
Problem
Existing photovoltaic assembly turnover machines lack precision in positioning and risk of hidden cracking due to high center of gravity and inadequate control over the distance between the short edges and the pallet during vertical turnover, leading to potential damage during the turnover process.
Innovation Solution
A high-precision vertical turnover machine with a two-step turnover process, utilizing a first drum conveyor line, horizontal transfer mechanism, first and second turnover mechanisms, distance detecting sensors, and a lifting correction transfer mechanism to ensure precise positioning and controlled distance adjustments, reducing the risk of damage by using a long edge as the initial turnover edge and a right-angle corner as the turnover center.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If photovoltaic assemblies are turned over directly from horizontal stacked state to vertical state with short edges as bottom, then turnover speed is improved, but positioning precision deteriorates
Solution Approach 1:
The turnover process is divided into two distinct stages: first horizontal turnover to vertical state with long edges as bottom, then vertical turnover with short edges as bottom. This segmentation allows each stage to be optimized independently, ensuring both speed and precision requirements are met.
Solution Approach 2:
The horizontal turnover mechanism performs preliminary positioning of photovoltaic assemblies before they enter the vertical turnover machine. This preliminary action ensures that assemblies are correctly oriented and positioned, enabling the vertical turnover to proceed quickly and accurately without compromising precision.
2Reliability
If distance between short edges and pallet surface is controlled strictly, then hidden cracking is prevented, but device complexity increases
Solution Approach 1:
A distance detection sensor is introduced as an intermediary device to automatically measure and control the distance between short edges and pallet surface. This intermediary enables precise control without requiring complex mechanical control systems, as the sensor provides real-time feedback for automated adjustment.
Solution Approach 2:
The patent replaces complex mechanical control systems with automated detection and control mechanisms. The distance detection sensor combined with automated control systems substitutes for manual or mechanically complex distance management, simplifying the overall control architecture while improving reliability.
3Productivity
If photovoltaic assemblies are turned over with high center of gravity, then turnover efficiency is improved, but stability deteriorates
Solution Approach 1:
The turnover process is segmented into horizontal and vertical stages, with each stage having optimized stability characteristics. The horizontal turnover stage prepares the assembly with proper orientation, while the vertical turnover stage executes the final positioning, distributing the stability requirements across multiple controlled stages.
Solution Approach 2:
The horizontal turnover mechanism performs preliminary stabilization of photovoltaic assemblies before they enter the vertical turnover machine. This beforehand cushioning ensures assemblies are properly supported and oriented, reducing instability risks during the subsequent vertical turnover operation.
Data Source
AI summary
A high-precision vertical turnover machine for packaging a photovoltaic assembly includes a first drum conveyor line, a horizontal transfer mechanism driving the first drum conveyor line to move left and right between a receiving station and a first turnover station, a first turnover mechanism located on the left side of the first drum conveyor line, a second turnover mechanism located on the left side of the first turnover mechanism, a distance detecting sensor detecting the distance of the front surface of the photovoltaic assembly on the first turnover mechanism or the distance of the rear surface of the photovoltaic assembly on the first turnover mechanism, and a lifting correction transfer mechanism moving, according to a detection result of the distance detecting sensor, the photovoltaic assembly on the first turnover mechanism to a second turnover station and placing the photovoltaic assembly on the second turnover mechanism precisely.