Solar Cell Stringer Calibration via Sensor Feedback
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Solution Overview
Problem
Current solar cell stringer calibration methods are inefficient and prone to misalignment, leading to reduced solar cell efficiency and increased reworking due to inadequate pressure and temperature control, as well as inaccurate alignment of soldering coils and pyrometers.
Innovation Solution
Implementing a calibration system with pressure sensors, temperature sensors, and current sensors to measure and adjust the tacking head, induction soldering coil, and pyrometer positions relative to solder joints, ensuring alignment and optimal operating conditions within predetermined ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional calibration methods are used for solar cell stringers, then the calibration process is simple, but misalignment occurs leading to reduced solar cell efficiency and increased reworking
Solution Approach 1:
The patent replaces manual mechanical calibration methods with an automated calibration system that uses sensors (pressure sensors, temperature sensors, current sensors) and a controller to automatically adjust and verify the positions of the tacking head, induction soldering coil, and pyrometer. This substitution of mechanical manual adjustment with an automated sensor-based system resolves the contradiction by achieving high alignment accuracy through precise sensor feedback while managing complexity through systematic automation.
Solution Approach 2:
The calibration system performs self-verification through sensors that automatically detect the positions and operating conditions of the tacking head, induction soldering coil, and pyrometer. The controller processes sensor data and automatically adjusts components to achieve proper alignment and operating parameters without requiring constant manual intervention, enabling the system to self-correct and maintain calibration accuracy.
2Reliability
If manual calibration is performed, then the system is easier to operate, but pressure and temperature control are inadequate leading to reworking
Solution Approach 1:
The patent implements feedback control through pressure sensors, temperature sensors, and current sensors that continuously monitor the operating conditions of the tacking head, induction soldering coil, and pyrometer. The controller receives this sensor data and automatically adjusts the positions and operating parameters to maintain pressure and temperature within specified ranges. This feedback mechanism ensures reliable pressure and temperature control while the automation reduces operational difficulty by eliminating manual trial-and-error calibration.
Solution Approach 2:
Manual pressure and temperature control methods are replaced with an automated sensor-based control system. Pressure sensors measure the force applied by the tacking head, temperature sensors monitor the heating from the induction soldering coil and pyrometer, and the controller automatically adjusts these parameters. This substitution ensures consistent and reliable control of pressure and temperature while reducing the skill and effort required for operation.
3Manufacturing precision
If precise alignment of soldering coils and pyrometers is achieved, then soldering quality improves, but the calibration process becomes more complex
Solution Approach 1:
The patent introduces current sensors as intermediary measurement devices that indirectly measure the alignment of the induction soldering coil and pyrometer by detecting the current induced in a metal coil or bar during induction heating. This intermediary measurement approach simplifies the alignment verification process compared to direct optical or mechanical measurement methods, as the current sensor provides quantitative feedback on the magnetic field coupling and thus the relative positioning of the soldering coil and workpiece.
Solution Approach 2:
Traditional mechanical alignment measurement methods are replaced with sensor-based measurement and control. The system uses pressure sensors, temperature sensors, and current sensors to automatically detect and verify the alignment of the tacking head, induction soldering coil, and pyrometer. The controller processes this data and automatically adjusts positions to achieve precise alignment. This substitution improves soldering quality through consistent precise alignment while managing the complexity through systematic automated measurement and control.
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
This approach ensures accurate and uniform pressure and temperature application, minimizing misalignment and reworking, thereby improving solar cell stringer throughput and quality.
Implementation Method 1
passing an AC current through an induction soldering coil positioned above a solder joint of the loaded solar cells. The controller measures a current in a metal coil or bar disposed under the solder joint during the induction heating
Implementation Method 2
measuring the temperature of the solder joint with a pyrometer and a temperature sensor disposed under the solder joint
Implementation Method 3
measuring the temperature of the solder joint with a pyrometer
Implementation Method 4
measuring the force applied by the tacking head with a pressure sensor
Data Source
AI summary
A solar cell stringer calibrator has been disclosed. In an example, a method includes loading a base having pressure sensors into a solar cell stringer to be positioned under a tacking head. The tacking head is lowered onto the base. The pressure sensors measure pressure applied by the tacking head. The method involves determining whether the pressure applied by the tacking head is within a predetermined range. In another example, a method involves heating a solder joint, and measuring a temperature of the solder joint with a pyrometer and a temperature sensor, the temperature sensor disposed under the solder joint. The location of the pyrometer relative to the solder joint is determined based on a difference in temperatures measured with the pyrometer and the temperature sensor. The method involves adjusting the solar cell stringer if the location of the pyrometer is determined to be outside a predetermined range.