Solar Cell Alignment via Dual-Stage Orientation Detection
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Solution Overview
Problem
Accurate alignment of lightweight solar cell elements during the assembly of solar cell modules is challenging due to their lightweight nature, which can lead to misalignment and reduced module efficiency.
Innovation Solution
An apparatus and method that utilize a transfer device with a detection system to detect and adjust the orientation of solar cell elements twice during transfer, ensuring precise alignment on a support device, using a controller to align the elements based on detected orientations, and a gripper to securely move and position them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If solar cell elements are assembled without alignment detection and adjustment, then the assembly process is simpler and faster, but the alignment precision deteriorates leading to misalignment and reduced module efficiency
Solution Approach 1:
The detection device detects the orientation of solar cell elements before they are transferred and assembled. The controller pre-calculates the required orientation adjustment based on the detected orientation, so that when the element is transferred by the transfer device, it can be directly positioned in the correct orientation without requiring complex real-time adjustment mechanisms during assembly.
Solution Approach 2:
The detection device provides feedback information about the actual orientation of each solar cell element to the controller. The controller uses this feedback to determine the precise orientation adjustment needed and controls the transfer device to apply the correct adjustment, creating a closed-loop system that ensures high alignment precision.
2Manufacturing precision
If a detection device and controller are added to align solar cell elements, then alignment precision improves, but the device complexity and cost increase
Solution Approach 1:
The system replaces complex mechanical alignment mechanisms with a combination of optical/electronic detection and intelligent control. Instead of using complex mechanical guides, adjustment mechanisms, or manual alignment tools, the invention uses a detection device to sense element orientation and a controller with transfer device to intelligently position elements, simplifying the overall system architecture while achieving high precision.
3Measurement precision
If solar cell elements are transferred without orientation detection, then the transfer process is simpler, but the positioning accuracy deteriorates
Solution Approach 1:
The solar cell elements essentially perform self-alignment through the system. The detection device measures the element's own orientation, the controller calculates the required adjustment, and the transfer device executes the positioning. This eliminates the need for external alignment fixtures or complex mechanical guidance systems, as the element's orientation information is used directly to achieve proper positioning.
Data Source
AI summary
The present disclosure provides an apparatus for aligning a solar cell element. The apparatus includes a transfer device configured for moving the solar cell element from a first position on a transport device to a second position on a support device, a detection device configured to detect a first orientation of the solar cell element on the transport device and configured to detect a second orientation of the solar cell element held by the transfer device, and a controller configured to change an orientation of the solar cell element held by the transfer device based on at least one of the first orientation and the second orientation to align the solar cell element.