CN102528203B - Semi-automatic single welding machine for solar cell slices - Google Patents
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Abstract
一种太阳能电池片的半自动单焊机,包括有机座,其特征在于:机座沿长度方向依次设置有焊带固定装置;焊带校直装置;送料装置;助焊剂涂覆装置;助焊剂烘干装置;焊带切断装置,包括有刀架、第一压紧装置、切刀和焊头,刀架的底部还设置有砧板;以及焊带牵引装置,包括有可固定焊带的第二压紧装置和能控制该第二压紧装置在焊带的被切断位置和焊接工位之间来回移动的驱动装置。本发明代替全手工操作而实现了太阳能电池片的半自动单焊工艺,整体结构紧凑,投入成本低,不仅提高了工作效率,节省了劳动力,而且焊接质量通过机械化操作有所保证,能够更好地满足中小型光伏企业的产品升级需求,具有较广泛的市场应用前景。
A semi-automatic single welding machine for solar cells, including an organic base, characterized in that: the base is sequentially provided with a welding ribbon fixing device along the length direction; a welding ribbon straightening device; a feeding device; a flux coating device; Drying device; welding ribbon cutting device, including a knife holder, a first pressing device, a cutter and a welding head, the bottom of the knife holder is also provided with an anvil; A tightening device and a driving device that can control the second pressing device to move back and forth between the cut-off position of the welding strip and the welding station. The present invention realizes the semi-automatic single-welding process of solar cells instead of manual operation. The overall structure is compact and the input cost is low. It meets the product upgrading needs of small and medium-sized photovoltaic enterprises and has a wider market application prospect.
Description
技术领域 technical field
本发明涉及一种焊机设备,特别是一种用于太阳能电池片的半自动单焊机。The invention relates to a welding machine equipment, in particular to a semi-automatic single welding machine for solar cells.
背景技术 Background technique
现有技术中,利用太阳能的最佳方式之一是光伏转换(光伏效应),就是使太阳光射到硅材料上产生电流直接发电,这种发电方式通常是使用光伏组件实现,光伏组件是一种暴露在阳光下便会产生电流的发电装置,由几乎全部以半导体物料(例如硅)制成的固体光伏电池组成,可长时间使用而不会导致任何损耗。In the existing technology, one of the best ways to use solar energy is photovoltaic conversion (photovoltaic effect), which is to make sunlight shine on silicon materials to generate electricity directly. This power generation method is usually realized by using photovoltaic modules. Photovoltaic modules are a A power generating device that generates electricity when exposed to sunlight, consisting of solid photovoltaic cells made almost entirely of semiconductor materials such as silicon, which can be used for a long time without causing any wear and tear.
组件板的封装技术是光伏组件的关键技术之一,在组件板的封装流程中,正面负极焊接俗称单焊,是一种在电池片主栅线上的焊接,其焊接时首先将焊带涂覆助焊剂并烘干,再将电池片放置到预热板上预热到40-50摄氏度,接着将焊带放置到电池片主栅线的合适位置(通常是焊带距离电池片最左端2-3mm),使得焊带中心线与主栅线中心线重合,然后用电烙铁顺着主栅线方向滑动并焊牢整条焊带,整个焊接过程需要十分精密的操作和控制,否则很容易产生产品质量问题。The packaging technology of the module board is one of the key technologies of photovoltaic modules. In the packaging process of the module board, the welding of the front and negative electrodes is commonly known as single welding. It is a kind of welding on the main grid line of the battery. Cover the flux and dry it, then place the cell on the preheating plate to preheat to 40-50 degrees Celsius, and then place the soldering strip on the appropriate position of the main grid line of the cell (usually the soldering strip is 2 -3mm), so that the centerline of the ribbon coincides with the centerline of the busbar, then slide the soldering iron along the direction of the busbar and weld the entire ribbon firmly. The whole welding process requires very precise operation and control, otherwise it will be easy product quality problems.
目前,太阳能电池片的单焊主要通过手工焊接完成,通过人工操作来保证焊接的定位精度,并控制碎片率低于0.3%,虽然能够保证产量,但是,人工操作过程无法提高工作效率,而且,全人工焊接方式对于操作者的要求很高,不容易控制产品的质量。另外,国外已开发出全自动焊接设备,如德国IMA公司生产的全自动焊接机、西班牙GOROSABEL公司生产的SL系列焊接机、德国帝目公司生产的TT1200高速串焊机以及日本NPC公司生产的NTS-150-STD全自动焊接机等,这些全自动焊接机虽然能够实现自动化操作,但是一台设备动辄好几百万,投入成本和维护成本都非常高,而且相对于这样高投入的成本,产量未见得有所大幅度提高,因此对于我国中小型企业来说,这样的全自动焊接设备也是不适用的。At present, the single welding of solar cells is mainly completed by manual welding. Manual operation is used to ensure the positioning accuracy of welding and control the debris rate below 0.3%. Although the output can be guaranteed, the manual operation process cannot improve work efficiency. Moreover, The fully manual welding method has high requirements for the operator, and it is not easy to control the quality of the product. In addition, foreign countries have developed fully automatic welding equipment, such as the fully automatic welding machine produced by the German IMA company, the SL series welding machine produced by the Spanish GOROSABEL company, the TT1200 high-speed serial welding machine produced by the German Dime company, and the NTS produced by the Japanese NPC company. -150-STD automatic welding machine, etc. Although these automatic welding machines can realize automatic operation, but a piece of equipment costs several million, the input cost and maintenance cost are very high, and compared to such a high input cost, the output It has not necessarily been greatly improved, so for small and medium-sized enterprises in our country, such fully automatic welding equipment is not applicable.
发明内容 Contents of the invention
本发明所要解决的技术问题是针对上述现有技术现状而提供一种能够代替手工实现焊接且生产率高、投入成本低的太阳能电池片的半自动单焊机。The technical problem to be solved by the present invention is to provide a semi-automatic single welding machine for solar cells that can replace manual welding and has high productivity and low investment cost.
本发明解决上述技术问题所采用的技术方案为:一种太阳能电池片的半自动单焊机,包括有机座,所述的太阳能电池片放置于该机座的焊接工位上,其特征在于:所述的机座沿长度方向依次设置有The technical solution adopted by the present invention to solve the above-mentioned technical problems is: a semi-automatic single welding machine for solar cells, which includes an organic base, and the solar cells are placed on the welding station of the base, which is characterized in that: The above machine base is sequentially arranged along the length direction with
焊带固定装置,用于设置筒状焊带;The ribbon fixing device is used to set the cylindrical ribbon;
焊带校直装置,将所述的筒状焊带进行拉直处理;A welding ribbon straightening device, which straightens the cylindrical welding ribbon;
送料装置,驱动所述焊带自动向前输送;A feeding device, which drives the welding ribbon to be automatically conveyed forward;
助焊剂涂覆装置,将助焊剂涂抹到所述焊带上;A soldering flux coating device, which applies flux to the soldering strip;
助焊剂烘干装置,对涂抹有助焊剂的所述焊带进行干燥处理;The flux drying device is used to dry the solder strip coated with flux;
焊带切断装置,包括有刀架、用于固定所述焊带的第一压紧装置和能沿竖直方向移动而用来切断所述焊带的切刀,所述刀架的底部还设置有能与该切刀相抵而实现所述焊带切断的砧板;The welding ribbon cutting device includes a knife rest, a first pressing device for fixing the welding ribbon, and a cutting knife that can move in the vertical direction and is used to cut off the welding ribbon. The bottom of the knife rest is also provided with There is an anvil block capable of abutting against the cutter to realize the cutting of the welding ribbon;
焊头,将被切断的所述焊带焊接到所述太阳能电池片上;a welding head, welding the cut ribbon to the solar battery sheet;
焊带牵引装置,确定所述焊带的被切断长度,包括有可固定焊带的第二压紧装置和能控制该第二压紧装置在所述焊带的被切断位置和焊接工位之间来回移动的驱动装置,以将切断后的所述焊带定位在位于所述焊接工位上的太阳能电池片沿主栅线的焊接位置。The welding ribbon pulling device determines the cut length of the welding ribbon, and includes a second pressing device that can fix the welding ribbon and can control the second pressing device between the cut position of the welding ribbon and the welding station. A drive device that moves back and forth between the cut-off ribbons is positioned at the welding position of the solar cells on the welding station along the busbar.
为了保证助焊剂能够均匀地涂覆到焊带的上下表面,作为优选,所述的助焊剂涂覆装置包括有容器、毛毡和送液装置,其中,所述的容器位于所述毛毡的上方,该容器内盛放有助焊剂,所述焊带穿设于所述毛毡中,所述送液装置具有连接所述容器的输入端和连接所述毛毡的输出端。由于盛放助焊剂的容器是高于毛毡设置,使得助焊剂能够自动输送至毛毡上,通过毛毡渗透到焊带上,保证焊带均匀地涂覆上助焊剂。In order to ensure that the flux can be evenly applied to the upper and lower surfaces of the solder strip, preferably, the flux coating device includes a container, a felt and a liquid delivery device, wherein the container is located above the felt, Flux is contained in the container, the welding ribbon is passed through the felt, and the liquid delivery device has an input end connected with the container and an output end connected with the felt. Since the container containing the flux is set higher than the felt, the flux can be automatically transported to the felt, and penetrates into the welding ribbon through the felt to ensure that the flux is evenly coated on the welding ribbon.
为了在焊带的一次切断后,方便下一次切断前的牵拉,作为优选,所述的砧板为一由动力源驱动而能沿所述机座的长度方向来回移动的滑动部件,在所述切刀处于切割状态下,所述砧板向前移动至所述切刀的下方,所述第一压紧装置压紧所述焊带;在所述切刀处于抬起状态下,所述第一压紧装置松开所述焊带,所述砧板向后移动至所述切刀的内侧。于是,通过动力源可以驱动砧板沿机座长度方向来回的移动,当砧板退回初始位置时,焊带的头部具有一定的余量,方便焊带牵引装置的下一次牵拉。In order to facilitate the pulling before the next cutting after one cutting of the welding ribbon, preferably, the cutting board is a sliding part driven by a power source and can move back and forth along the length direction of the machine base. When the cutting knife is in the cutting state, the anvil block moves forward to the bottom of the cutting knife, and the first pressing device presses the welding ribbon; when the cutting knife is in the lifting state, the first The hold-down device releases the ribbon and the anvil moves back to the inside of the cutter. Therefore, the cutting board can be driven by the power source to move back and forth along the length direction of the machine base. When the cutting board returns to the initial position, the head of the welding ribbon has a certain margin, which is convenient for the next pulling of the welding ribbon pulling device.
为了方便控制和操作,作为优选,所述的第一压紧装置包括有对应每一条焊带设置的第一电磁铁和由每一所述第一电磁铁驱动的可竖直移动的第一压杆,所述第一压杆的底部设置有第一压头,并且,所述第一压头的底部还设置有能与该第一压头紧抵的第一压条。于是,第一电磁铁可以实现对第一压头的升降控制,保证了动作执行的可靠性和准确性。In order to facilitate control and operation, preferably, the first pressing device includes a first electromagnet corresponding to each welding strip and a vertically movable first pressing device driven by each first electromagnet. Rod, the bottom of the first pressing rod is provided with a first pressing head, and the bottom of the first pressing head is also provided with a first pressing bar that can be pressed against the first pressing head. Therefore, the first electromagnet can control the lifting of the first pressure head, which ensures the reliability and accuracy of action execution.
为了保证第二压紧装置的整体可移动性,作为优选,所述的第二压紧装置包括有支架,所述支架上设置有对应每一条焊带设置的多个第二电磁铁和有相应的第二电磁铁驱动下可竖直移动的第二压杆,所述第二压杆的底部设置有第二压头,并且,所述支架的底部还形成有能与所述第二压头紧抵的第二压条。于是,第二电磁铁、第二压杆和第二压头可以随着支架一起在驱动装置的驱动下来回移动。In order to ensure the overall mobility of the second pressing device, preferably, the second pressing device includes a bracket, and the bracket is provided with a plurality of second electromagnets corresponding to each welding strip and corresponding Driven by the second electromagnet, the second pressure rod can move vertically, the bottom of the second pressure rod is provided with a second pressure head, and the bottom of the bracket is also formed with a Tight second bead. Therefore, the second electromagnet, the second pressing rod and the second pressing head can move back and forth together with the bracket driven by the driving device.
为了简化设备,并提高驱动装置的控制精度,作为优选,所述的驱动装置包括有设置于所述机座底部的电机和由该电机驱动的直线滑台,所述机座沿长度方向还开设有一滑槽,所述直线滑台的输出端和所述支架之间通过一驱动臂相连。简单地,所述驱动装置也可以通过丝杠螺母副等其他传动机构实现。In order to simplify the equipment and improve the control accuracy of the driving device, preferably, the driving device includes a motor arranged at the bottom of the base and a linear slide driven by the motor, and the base is also provided along the length direction There is a chute, and the output end of the linear slide table is connected with the support through a driving arm. Simply, the driving device can also be realized by other transmission mechanisms such as lead screw and nut pairs.
为了保证被切断焊带与太阳能电池片主栅线之间的精确位置关系,提高焊接质量,作为优选,所述焊带在被切断位置和焊接工位之间还设置有可引导被切断焊带始终沿所述太阳能电池片的主栅线方向移动的导向定位装置,所述的导向定位装置包括有多个导向块,每一所述导向块对应太阳能电池片上的一条主栅线,并且,每一所述导向块的顶部开设有能与太阳能电池片的相应主栅线对齐的导槽,所述导槽的底部开设有可产生负压的气孔,所述气孔上设置有可吸住所述焊带的吸盘。于是,导向块上的导槽能够对焊带起到有效的导向作用,防止焊带在牵拉过程中偏离电池片的主栅线位置,而且,当导向块连接真空发生器后,导槽内的气孔产生负压,通过吸盘能够将焊带吸附在导向块的导槽上,起到固定焊带的作用,防止焊接时焊带的移位,保证焊接精度,提高产品质量。In order to ensure the precise positional relationship between the cut off ribbon and the busbar of the solar cell, and improve the welding quality, preferably, the weld ribbon is also provided with a guide between the cut off position and the welding station. A guiding and positioning device that always moves along the direction of the busbar of the solar cell, the said guiding and positioning device includes a plurality of guide blocks, each of which corresponds to a busbar on the solar cell, and each The top of the guide block is provided with a guide groove that can be aligned with the corresponding busbar of the solar battery sheet, and the bottom of the guide groove is provided with air holes that can generate negative pressure, and the air holes are provided with holes that can absorb the solder. with suction cups. Therefore, the guide groove on the guide block can effectively guide the ribbon, preventing the ribbon from deviating from the position of the main grid line of the cell during the pulling process. Moreover, when the guide block is connected to the vacuum generator, the inside of the guide groove The pores of the air hole generate negative pressure, and the welding ribbon can be adsorbed on the guide groove of the guide block through the suction cup, which can fix the welding ribbon, prevent the welding ribbon from shifting during welding, ensure welding accuracy, and improve product quality.
考虑到不同规格的太阳能电池片,其主栅线之间的间隔距离有所不同,为了方便导向块相对位置的调节,作为优选,所述的导向块可滑动地设置于沿所述机座的宽度方向设置的导向杆上,所述导向杆的两端分别连接有支座,所述支座固定连接在所述机座上。于是,导向块可以沿导向杆的轴线方向移动,以便于将导向块调节到和电池片主栅线相对应的位置。Considering that the distance between the main grid lines of solar cells of different specifications is different, in order to facilitate the adjustment of the relative position of the guide block, as a preference, the guide block is slidably arranged on the On the guide rod arranged in the width direction, two ends of the guide rod are respectively connected with supports, and the supports are fixedly connected to the machine base. Therefore, the guide block can move along the axis direction of the guide rod, so as to adjust the guide block to a position corresponding to the bus bar of the cell.
考虑到焊接前后的温差变化对太阳能电池片的影响,为了减少电池片的温差变形,保证电池片的最佳性能,作为优选,所述的机座在邻近所述太阳能电池片的焊接工位处还设置有电池片预热装置。Considering the impact of the temperature difference before and after welding on the solar cells, in order to reduce the temperature difference deformation of the cells and ensure the best performance of the cells, preferably, the base is located at the welding station adjacent to the solar cells A cell preheating device is also provided.
作为进一步优选,简单地,所述的电池片预热装置为一预热板,所述预热板上设置有控制电池片温度的温控装置。于是,等待加工的电池片可以通过叠加的方式预先放置在预热板上进行预热,预热的温度可以通过温控装置进行控制和调节。As a further preference, simply, the cell preheating device is a preheating plate, and the preheating plate is provided with a temperature control device for controlling the temperature of the cell. Therefore, the battery slices waiting to be processed can be preheated by placing them on the preheating plate in a stacked manner, and the preheating temperature can be controlled and adjusted by the temperature control device.
与现有技术相比,本发明的优点在于:首先,代替全手工操作而实现了太阳能电池片的半自动单焊工艺,设备的整体结构紧凑,投入成本低,不仅提高了工作效率,节省了劳动力,而且焊接质量通过机械化操作有所保证,能够更好地满足中小型光伏企业的产品升级需求,具有较广泛的市场应用前景;其次,助焊剂涂覆装置采用滴液式结构,不仅实现了助焊剂的自动加注,而且能够保证焊带上助焊剂能够涂抹更加均匀,确保焊接质量;另外,采用了导向定位装置,能够对焊带起到有效地引导定位作用,防止焊带偏离太阳能电池片的主栅线方向,保证焊接的精度,从而提高了产品质量。Compared with the prior art, the present invention has the following advantages: Firstly, instead of manual operation, the semi-automatic single welding process of solar cells is realized, the overall structure of the equipment is compact, and the input cost is low, which not only improves work efficiency, but also saves labor , and the welding quality is guaranteed by mechanized operation, which can better meet the product upgrading needs of small and medium-sized photovoltaic enterprises and has a wider market application prospect; secondly, the flux coating device adopts a dripping structure, which not only realizes the help The automatic filling of flux can ensure that the flux on the ribbon can be applied more evenly to ensure the welding quality; in addition, a guiding and positioning device is used to effectively guide and position the ribbon to prevent the ribbon from deviating from the solar cells The direction of the main grid line ensures the accuracy of welding, thereby improving product quality.
附图说明 Description of drawings
图1为本发明实施例的整体结构示意图。Fig. 1 is a schematic diagram of the overall structure of an embodiment of the present invention.
图2为图1所示整体结构的俯视图。FIG. 2 is a top view of the overall structure shown in FIG. 1 .
图3为本发明实施例的助焊剂涂覆装置结构示意图。Fig. 3 is a schematic structural diagram of a flux coating device according to an embodiment of the present invention.
图4为本发明实施例的焊带切断装置结构示意图之一。Fig. 4 is one of the structural schematic diagrams of the welding ribbon cutting device according to the embodiment of the present invention.
图5为本发明实施例的焊带切断装置结构示意图之二。Fig. 5 is the second schematic diagram of the structure of the welding ribbon cutting device according to the embodiment of the present invention.
图6为图4所示的A-A向剖视图之一(切刀未动作状态)。Fig. 6 is one of the cross-sectional views along the line A-A shown in Fig. 4 (the cutting knife is not in action).
图7为图4所示的A-A向剖视图之二(切刀切断焊带状态)。Fig. 7 is the second sectional view along the line A-A shown in Fig. 4 (state where the cutter cuts the welding strip).
图8为本发明实施例的焊带牵引装置结构示意图。Fig. 8 is a schematic structural diagram of a ribbon pulling device according to an embodiment of the present invention.
图9为本发明实施例的第二压紧装置的结构示意图。Fig. 9 is a schematic structural diagram of a second pressing device according to an embodiment of the present invention.
图10为本发明实施例的第一压紧装置和第二压紧装置的压头结构示意图之一。Fig. 10 is one of the structural schematic diagrams of the first pressing device and the second pressing device according to the embodiment of the present invention.
图11为本发明实施例的第一压紧装置和第二压紧装置的压头结构示意图之二。Fig. 11 is the second schematic diagram of the structure of the pressing head of the first pressing device and the second pressing device according to the embodiment of the present invention.
具体实施方式 Detailed ways
以下结合附图实施例对本发明作进一步详细描述。The present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments.
如图1~图11所示,为一种用于太阳能电池片的半自动单焊机,本实施例的单焊机通过机械化装置和电气化控制实现了焊带的自动输送和自动焊接,而太阳能电池片的取放则采用人工操作,通过人工操作和机械化操作相结合,实现了太阳能电池片的半自动单焊。As shown in Figures 1 to 11, it is a semi-automatic single welding machine for solar cells. The single welding machine in this embodiment realizes automatic transportation and automatic welding of welding strips through mechanized devices and electrified control, while solar cells The pick-and-place of the sheet is manually operated, and the semi-automatic single welding of the solar cell is realized through the combination of manual operation and mechanized operation.
本实施例的单焊机包括有机座A,机座A上设置有焊接工位,工作时,通过手工操作将太阳能电池片C放置到焊接工位上,焊接完毕后,也通过手动操作将电池片C从焊接工位取出;考虑到焊接时温度升高,为了防止太阳能电池片C的温差变形,减小常温下和焊接时的太阳能电池片C的温度差,机座A在太阳能电池片C的焊接工位和邻近焊接工位的一侧分别设置有电池片C预热装置,该预热装置为一块固定于机座A上的预热板B,参见图2,已加工完和未加工的太阳能电池片C可以分别放置在不同的预热板B上保温或加热,并且,在预热板B上还设置有控制电池片C加热温度的温控装置。The single welding machine of this embodiment includes an organic base A, and a welding station is arranged on the machine base A. When working, the solar battery sheet C is placed on the welding station by manual operation. After the welding is completed, the battery is also manually operated. Sheet C is taken out from the welding station; considering the temperature rise during welding, in order to prevent the temperature difference deformation of solar cell C and reduce the temperature difference between the normal temperature and the solar cell C during welding, base A is placed on the solar cell C The welding station and the side adjacent to the welding station are respectively equipped with a battery slice C preheating device. The preheating device is a preheating plate B fixed on the machine base A, see Figure 2, processed and unprocessed The solar cells C can be respectively placed on different preheating plates B to keep warm or heated, and the preheating plate B is also provided with a temperature control device for controlling the heating temperature of the cells C.
本实施例单焊机的机座A沿长度方向(即焊带D输送方向)依次设置有焊带固定装置1、焊带校直装置2、送料装置3、助焊剂涂覆装置4、助焊剂烘干装置5、焊带切断装置6和焊带牵引装置7,在此,焊带固定装置1、焊带校直装置2、送料装置3、助焊剂烘干装置5为常规技术,可以采用现有技术中的各种相关设备实现,也可以采用本实施例图中所示的结构实现。The base A of the single welding machine in this embodiment is sequentially provided with a welding ribbon fixing device 1, a welding
其中,焊带固定装置1用于安装卷绕成筒状的焊带,如图1所示,本实施例的焊带固定装置1优选为一框架结构,该框架结构上设置有多个横杆,卷绕成筒状的焊带即安装在合适高度的横杆上(图中未示),所需要焊带的安装筒数和间距根据被焊接的太阳能电池片C上的主栅线数量和间隔距离决定,焊带D的宽度要和电池片C的主栅线d1宽度一致,通常,太阳能电池片C多为两栅结构(主栅线d1有两条)或者三栅结构(主栅线d1有三条),本实施例的太阳能电池片C采用具有两条主栅线d1的电池片C。Wherein, the welding ribbon fixing device 1 is used to install the welding ribbon wound into a cylindrical shape, as shown in Figure 1, the welding ribbon fixing device 1 of the present embodiment is preferably a frame structure, and the frame structure is provided with a plurality of cross bars , the ribbon wound into a tube is installed on a crossbar of a suitable height (not shown in the figure), and the number and spacing of the required ribbons are based on the number of busbars and the number of busbars on the solar cell C to be welded. Depending on the spacing distance, the width of the ribbon D should be consistent with the width of the main grid line d1 of the cell C. Usually, the solar cell C is mostly a two-grid structure (two main grid lines d1) or a three-grid structure (the main grid line d1 There are three d1), the solar cell C in this embodiment adopts the cell C with two main grid lines d1.
为了保证焊带D的平直,确保焊带D的助焊剂涂覆质量和焊接质量,从焊带固定装置1拉出的焊带D需要经过焊带校直装置2进行拉直处理,焊带校直装置的结构可以通过现有的各种设备实现,本实施例简单地采用倾斜设置的框架,框架中间设置有多根相互平行设置的横档,焊带呈S形依次绕设在框架的各横档上。In order to ensure the straightness of the welding strip D and ensure the flux coating quality and welding quality of the welding strip D, the welding strip D pulled out from the welding strip fixing device 1 needs to be straightened by the welding
本实施例的送料装置3能够驱动焊带自动向前输送,该送料装置3包括有上辊轮31和下辊轮32,焊带D穿设于由上辊轮31和下辊轮32之间的间隙中,其中,上辊轮31可以上抬或下压,从而调整上辊轮31和下辊轮32之间的压紧力,上辊轮31和下辊轮32相互贴合后通过滚动摩擦产生一个对焊带D向前的拉力,进而实现对焊带D的自动输送,若要停止自动输送,则将上辊轮31抬起并离开下辊轮32即可。The feeding device 3 of this embodiment can drive the welding ribbon to be automatically conveyed forward. The feeding device 3 includes an upper roller 31 and a lower roller 32, and the welding ribbon D is passed between the upper roller 31 and the lower roller 32. In the gap, wherein, the upper roller 31 can be lifted or pressed down, so as to adjust the pressing force between the upper roller 31 and the lower roller 32, and the upper roller 31 and the lower roller 32 are attached to each other by rolling The friction produces a forward pulling force on the welding belt D, and then realizes the automatic delivery of the welding belt D. If the automatic delivery is to be stopped, the upper roller 31 is lifted and left from the lower roller 32.
助焊剂是焊接时使用的辅料,其主要作用是清除焊料和被焊母材表面的氧化物,使金属表面达到必要的清洁度,防止焊接时焊料表面的再次氧化,降低焊料的表面张力;为了提高焊接性能,焊带D在正式焊接到太阳能电池片C之前一般都需要涂抹助焊剂,本实施例通过助焊剂涂覆装置4将助焊剂涂抹到焊带D上;Flux is an auxiliary material used in welding. Its main function is to remove the oxides on the surface of the solder and the base metal to be welded, so that the metal surface can reach the necessary cleanliness, prevent the re-oxidation of the solder surface during welding, and reduce the surface tension of the solder; To improve the soldering performance, the soldering tape D generally needs to be coated with flux before it is formally welded to the solar cell C. In this embodiment, the soldering flux is applied to the soldering tape D through the flux coating device 4;
本实施例的助焊剂涂覆装置4包括有容器41、毛毡和送液装置,其中,容器41通过第一支撑杆411悬挂固定,该容器41内盛放有助焊剂;毛毡由相互贴靠于一起的上毛毡42和下毛毡43组成,焊带D穿设在上毛毡42和下毛毡43之间,为了更好地将上毛毡42和下毛毡43固定于一起,下毛毡43的底部设置有底板44,上毛毡42的上方设置有一与底板44固定的压板45,压板45和底板44之间通过螺钉相连;送液装置为一封闭的调节装置46,该调节装置46通过第二支撑杆464固定,调节装置46的两端分别连接有连通容器41的输入管461和输送至上毛毡42的输出管462,压板45的顶部还开设有可容纳送液装置的输出管462的导引槽451,输出管462的末端可以容置并限位于该导引槽451内,并且,调节装置46的一侧还设置有能控制输出管462流速的调节开关463,以便于调节输送到毛毡上的助焊剂的流量;The flux coating device 4 of this embodiment includes a
本实施例的助焊剂涂覆装置4采用点滴式结构,容器41、送液装置和毛毡之间从高到低形成一定的高度差,其中,第一支撑杆411的高度大于第二支撑杆464的高度,即容器41处于最高位,毛毡处于最低位,送液装置则位于容器41和毛毡之间的位置,于是,容器41内的助焊剂能够自动地添加到毛毡上,助焊剂通过毛毡的渗透再涂抹到焊带D上,焊带D由于从上毛毡42和下毛毡43之间穿过,使得焊带D的上表面和下表面都能够涂抹上助焊剂,保证了助焊剂的涂抹均匀性,保证了焊接质量,另外,通过送液装置的调节开关463还可以控制助焊剂的流量,操作简单,使用方便。The flux coating device 4 of this embodiment adopts a drip structure, and a certain height difference is formed between the
经过助焊剂涂覆装置4后的焊带D还需要经过助焊剂烘干装置5进行干燥处理,为了提高助焊剂活性,助焊剂烘干装置5的温度不能太高,以确保太阳能电池片C在长期工作条件下的可靠性,通常,理想的烘干温度为100℃,实际操作时,烘干温度一般控制在60℃左右。The solder strip D after passing through the flux coating device 4 also needs to be dried through the
本实施例的焊带切断装置6用于切断焊带D并将切断的焊带D焊接到太阳能电池片C上,焊带切断装置6包括有可供焊带D从底部穿过的刀架61、用于固定焊带D的第一压紧装置、能沿竖直方向移动的切刀62和焊头9,其中,焊头9可以采用现有技术中的各种装置实现,该焊头9设置于刀架61上并能沿该刀架61的竖直方向移动;The
第一压紧装置设置于刀架61与助焊剂烘干装置5相对而设的一侧,第一压紧装置包括有对应每一条焊带D设置的第一电磁铁63(一般为2~3个),每个第一电磁铁63上设置有由该第一电磁铁63驱动的可竖直移动的第一压杆64(通常外购的电磁铁本身就带有压杆),第一压杆64的底部设置有第一压头65,刀架61在第一压头65的底部还设置有能与该第一压头65紧抵的第一压条611,为了增大摩擦力,提高第一压头65的压紧效果,第一压头65的底部采用凹凸纹理结构,第一压头65的横截面可以采用各种形状,如方形、圆形、矩形或三角形等等,相应地,第一压条611的表面也做成凹凸面,当第一压头65与第一压条611相抵后,两者之间能够有更好的摩擦接触力,保证焊带D的压紧效果;The first pressing device is arranged on the side of the
为了在每次切断后,方便焊带牵引装置7的下一次牵拉,刀架61的底部还设置有能与该切刀62相抵的砧板66,该砧板66为一能沿机座A的长度方向来回移动的滑动部件,在刀架61的底部设置有一滑台气缸67,砧板66固定设置于滑台气缸67的缸体上并能随该缸体来回移动;在切刀62处于切割状态下,砧板66在滑台气缸67的驱动下向前移动至切刀62的下方,第一压紧装置压紧焊带D,切刀62下落与砧板66相抵,从而切断焊带D;在切刀62处于抬起状态下,第一压紧装置松开焊带D,砧板66在滑台气缸67的驱动下向后移动至切刀62的内侧,此时,砧板66与切刀62错位设置,砧板66退回后,位于砧板66前部的焊带D露出,能够方便焊带牵引装置7的下一次牵拉。In order to facilitate the next pull of the
本实施例的焊带牵引装置7主要实现将焊带D从焊带切断装置6的切割位置牵拉至焊接位置,不仅能够确定焊带D的被切断长度,而且能将被切断的焊带D定位到位于焊接工位上的太阳能电池片C沿主栅线d1的焊接位置;The welding
具体地,焊带牵引装置7包括有可固定焊带D的第二压紧装置和能控制该第二压紧装置在焊带D的被切断位置和焊接工位之间来回移动的驱动装置(可以采用现有技术中各种设备实现,图中未示),其中,第二压紧装置包括有呈L形的支架71,支架71的L形竖直板711上设置有对应每一条焊带D设置的多个第二电磁铁72(一般为2~3个),每个第二电磁铁72上设置有由该第二电磁铁72驱动的可竖直移动的第二压杆73(通常外购的电磁铁本身就带有压杆),第二压杆73的底部设置有第二压头74,支架71的L形水平底边形成能与第二压头74紧抵的第二压条712,该第二压紧装置和第一压紧装置类似,第二压头74的截面可以采用各种形状(如方形、圆形、椭圆形等等),为了增大摩擦力,第二压头74的底部也呈凹凸纹理结构,相应地,第二压条712的表面呈凹凸面;Specifically, the welding
为了提高精度,驱动装置包括有电机和由该电机驱动的直线滑台,机座A沿长度方向还开设有一滑槽a1,滑槽a1内设置有可带动支架71滑移的驱动臂75,其中,该驱动臂75的一端和直线滑台的输出端相连,该驱动臂75的另一端和支架71固定相连。驱动装置还可以采用直线滑台装置,能够进一步提高控制精度,简化设备安装。In order to improve the precision, the drive device includes a motor and a linear slide table driven by the motor. The base A also has a chute a1 along the length direction, and a drive arm 75 that can drive the
为了进一步提高焊接的精度,防止焊带D在牵拉过程中偏离太阳能电池片C的主栅线方向,本实施例在焊带D的被切断位置和焊接工位之间还设置有导向定位装置8,该导向定位装置8可引导被切断的焊带D始终沿对应的太阳能电池片C的主栅线方向移动;其中,导向定位装置8有包括有沿机座A的宽度方向设置的导向杆81和可滑动地设置在该导向杆81上的多个导向块82(通常为2~3个),导向杆81的两端分别支撑于支座83上,支座83固定连接在机座A上,每一导向块82对应太阳能电池片C上的一条主栅线,并且,每一导向块82都具有能与外部的真空发生器连接的吸气口821,每一导向块82的顶部开设有能太阳能电池片C的相应主栅线对齐的导槽822,导槽822的底部开设有气孔823,气孔823上设置有吸盘,当焊带牵引装置7拉着切断的焊带D向前运动过程中,焊带D能够沿着相对应的导槽822移动,起到导向作用,防止焊带D偏离主栅线位置,提高焊接的精度;而当导向块82向外排气时,导槽822上的气孔823产生负压,通过吸盘能够将焊带D吸住,从而起到固定焊带D的作用,保证焊带D焊接定位的可靠性和准确性。In order to further improve the welding accuracy and prevent the ribbon D from deviating from the busbar direction of the solar cell C during the pulling process, this embodiment also provides a guiding and positioning device between the cut position of the ribbon D and the
本实施例的单焊机工作过程为:The working process of the single welding machine of the present embodiment is:
(1)、启动送料装置3,安装在焊带固定装置1上的筒状焊带经过焊带校直装置2的缠绕拉直处理,由送料装置3驱动下自动向前输送;(1), start the feeding device 3, the cylindrical welding ribbon installed on the welding ribbon fixing device 1 is wound and straightened by the welding
(2)、焊带D进入助焊剂涂覆装置4进行助焊剂涂抹,再经过助焊剂烘干装置5进行干燥;(2), the welding strip D enters the flux coating device 4 to apply flux, and then dries through the
(3)、焊带D从焊带切断装置6的底部穿过,同时,焊带牵引装置7通过第二压紧装置将焊带D的前端固定,并从切割位置向前牵拉焊带D到需要焊接的长度,此时,将经过预热的太阳能电池片C手工放置到焊接工位;(3), the welding ribbon D passes through the bottom of the welding
(4)、启动第一压紧装置压紧焊带D,同时,送料装置3停止焊带D输送,砧板66在滑台气缸67的驱动下移动到切刀62下方,切刀62向下移动与砧板66相抵并切断焊带D,然后,第一压紧装置松开焊带D,接着,砧板66退回到切刀62的内侧;(4), start the first pressing device to compress the welding ribbon D, at the same time, the feeding device 3 stops the delivery of the welding ribbon D, and the cutting
(5)、焊带牵引装置7继续牵引切断的焊带D向前运动,并控制焊带D前端相对于太阳能电池片C的主栅线的焊接位置,切断的焊带D沿着导向定位装置8中对应导向块82的导槽822移动,防止焊带D偏离主栅线位置;;(5), the welding
(6)、当焊带牵引装置7移动定位后,导向块82排气,导向块82上的气孔823产生负压而将切断的焊带D吸住固定,焊带牵引装置7的第二压紧装置松开,随后,焊带牵引装置7退回到切割位置;(6), after the welding
(7)、焊带切断装置6上的焊头9加热、下落,并将切断的焊带D焊接到太阳能电池片C上,焊接完成后,焊头9退回,导向块82停止工作并将切断的焊带D松开,完成一次焊接循环。(7), the
为防止温差变形,焊完后的太阳能电池片C先手工移动到散热区,等待温度降低到合适范围后再进行下一道工序的加工。当需要进行下一个太阳能电池片C的焊接时,此时,重新启动送料装置3,重复上述的步骤(3)~(7),可以进行下一次的焊接循环。In order to prevent deformation due to temperature difference, the solar cells C after soldering are manually moved to the heat dissipation area, and the next process is performed after the temperature drops to an appropriate range. When it is necessary to weld the next solar cell C, at this time, the feeding device 3 is restarted, and the above steps (3)-(7) are repeated, and the next welding cycle can be performed.
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