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WO2023207131A1 - 薄膜高效自动铺设装置及铺设方法 - Google Patents

薄膜高效自动铺设装置及铺设方法 Download PDF

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Publication number
WO2023207131A1
WO2023207131A1 PCT/CN2022/138619 CN2022138619W WO2023207131A1 WO 2023207131 A1 WO2023207131 A1 WO 2023207131A1 CN 2022138619 W CN2022138619 W CN 2022138619W WO 2023207131 A1 WO2023207131 A1 WO 2023207131A1
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WO
WIPO (PCT)
Prior art keywords
film
plate
unit
laying
feeding unit
Prior art date
Application number
PCT/CN2022/138619
Other languages
English (en)
French (fr)
Inventor
毛吉亮
庞玉豪
杨明星
吴春新
Original Assignee
苏州晟成光伏设备有限公司
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Application filed by 苏州晟成光伏设备有限公司 filed Critical 苏州晟成光伏设备有限公司
Publication of WO2023207131A1 publication Critical patent/WO2023207131A1/zh

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    • H01L31/048—
    • H01L31/1876—

Definitions

  • This application belongs to the technical field of film coating equipment, and relates to, for example, an efficient automatic laying device and laying method of a film.
  • Solar modules are generally composed of one or two pieces of tempered glass, ethylene-vinyl acetate copolymer (Ethyl Vinyl Acetate, EVA) film and solar cell silicon wafers, which are laminated at high temperature by a laminator to form a composite layer, with wires between the cells.
  • EVA ethylene-vinyl acetate copolymer
  • Photovoltaic cell modules are formed by connecting series and parallel connections to the lead terminals.
  • one process is the laying of EVA film or polyvinyl fluoride structure (Tedlar/PET/Tedlar, TPT) film. Since most processes in the production of photovoltaic modules have been automated, the entire assembly production line is also automated. Assembly lines, therefore, have higher production cycle requirements for photovoltaic modules to meet efficient assembly line production.
  • automatic laying machines for EVA or TPT films generally include modules for film feeding, film feeding, film punching, film cutting, film pulling, and film support laying, such as the one disclosed in patent CN112850309A.
  • These photovoltaic module film automatic laying mechanisms basically use the pulling module to pull the film to the appropriate end position. During the pulling process, the film support laying module is used to drag the bottom of the film to prevent the middle of the film from sagging.
  • the film feeding module and the film cutting module are both fixed on the substrate.
  • the pulling module is set separately on a transfer mechanism for pulling, and the film support laying module must be used to better realize the film. Laying, the overall structure is relatively complex and there are many component modules;
  • This application provides an efficient automatic laying device and laying method for thin films, which have fewer structural modules, good laying effect and high laying efficiency.
  • embodiments of the present application provide an efficient automatic film laying device, which includes a plate conveying mechanism and a film laying mechanism disposed above the plate conveying mechanism; the film laying mechanism includes a first driving member, driven by the The first driving member drives the first support plate that moves horizontally, the film feeding unit and the cutting unit provided on the first support plate, and the tail end pressing unit that presses the film tail end on the surface of the plate, The cutting unit is located on the film output side of the film feeding unit.
  • embodiments of the present application provide an efficient automatic laying method of thin films, including:
  • a film feeding unit is used to clamp the end of the film and move it from one side of the plate to the other opposite side, maintaining a set height distance between the film and the plate; between the feeding direction of the film feeding unit and the horizontal plane Set at a set included angle;
  • the film feeding unit continues to output the film of the set length, so that the end edge of the film extends obliquely downward from the edge of the plate;
  • the film feeding unit moves a set distance backward horizontally, so that the end edge of the film adheres to the surface of the plate and moves to the initial position of film laying;
  • tail end pressing unit to press down the end of the film so that the end of the film is tightly attached to the surface of the plate and maintained;
  • a cutting unit is used to cut the film on the output side of the film feeding unit to complete the laying of the film.
  • Figure 1 is a schematic three-dimensional structural diagram of an embodiment of the present application.
  • Figure 2 is a schematic top view of the structure of an embodiment of the present application.
  • Figure 3 is a schematic structural diagram of the film laying mechanism in the embodiment of the present application.
  • Figure 4 is a schematic side structural view of the film feeding unit and cutting unit in the embodiment of the present application.
  • Figure 5 is a schematic structural diagram of the film feeding unit in the embodiment of the present application.
  • Figure 6 is a schematic structural diagram of the cutting unit in the embodiment of the present application.
  • Figure 7 is a schematic structural diagram of the cutting unit in the embodiment of the present application from another angle
  • Figure 8 is a schematic structural diagram of the plate conveying mechanism in the embodiment of the present application.
  • Figure 9 is a schematic structural diagram of the cache mechanism in the embodiment of the present application.
  • Figure 10 is a schematic structural diagram of a partial state when the film is laid in the embodiment of the present application.
  • Plate conveying mechanism 11. Conveying unit; 12. Plate positioning unit; 121. Front and rear positioning modules; 122. Left and right positioning modules; 13. Support rollers;
  • This embodiment is a high-efficiency automatic film laying device 100, which includes a plate conveying mechanism 1, a film laying mechanism 2 disposed above the plate conveying mechanism 1, and a film that feeds the film laying mechanism 2 The feeding mechanism 3, as well as the buffering mechanism 4 and the punching mechanism 5 provided in the film feeding mechanism 3 and the film laying mechanism 2.
  • the conveying direction of the plate conveying mechanism 1 is perpendicular to the laying direction of the film laying mechanism 2 .
  • the conveying direction of the plate conveying mechanism 1 can also be set parallel to the laying direction of the film laying mechanism 2 .
  • the plate conveying mechanism 1 includes a conveying unit 11 and a plate positioning unit 12 for positioning the surroundings of the plate on the conveying unit 11.
  • the plate positioning unit 12 includes a front and rear positioning module 121 and a left and right positioning module 122.
  • the plate conveying mechanism 1 can also adopt a conveying device with a positioning function around the plate in the related art, such as the "servo conveying and normalizing assembly" in an EVA cutting and laying machine disclosed in the patent publication number CN112390048A, or The patent publication number is CN215755272U, which discloses a conveyor mechanism composed of "conveyor lines and clamping regular components" in a high-efficiency solar large module vertical stacker equipment.
  • the film laying mechanism 2 includes a first driving member 21, a first supporting plate 22 driven by the first driving member 21 to move perpendicular to the conveying direction of the plate conveying mechanism 1, a film feeding unit 23 arranged on the first supporting plate 22 and a cutting unit 23.
  • the unit 24 and the tail end pressing unit 25 located on one side of the plate conveying mechanism 1 clamp the film tail end, and the cutting unit 24 is located on the film output side 238 of the film feeding unit 23 .
  • the film output by the film feeding mechanism 3 passes through the film feeding unit 23 and the cutting unit 24.
  • the film feeding unit 23 clamps the end of the film and then removes it from the end of the plate under the transfer driving of the first driving member 21.
  • One side moves to the other opposite side, and then the film feeding unit 23 outputs the film of the set length, so that the end of the film extends into the clamping range of the tail end pressing unit 25, and then the tail end pressing unit 25
  • the film feeding unit 23 and the cutting unit 24 return to the original side of the plate under the transfer driving of the first driving member 21, and cut the film through the cutting unit 24 to complete the laying of the film.
  • the film output side 238 of the film laying mechanism 2 is in contact with the plate. There is a height difference of a set distance between them.
  • the tail end pressing unit 25 in this embodiment directly presses the film on the plate.
  • the plate here can be a glass plate or a battery plate.
  • the position where the film is laid is subject to the force conveyed by the film feeding unit 23, so that the film at the pasting position is pressed to a certain extent.
  • the film is firmly attached to the board, thereby greatly improving the film laying effect; and the film feeding unit 23 is used to strictly control the transportation of the film, so that the film can maintain a completely flat state, and the film laying on the surface of the board is completed.
  • the film feeding unit 23 maintains a feeding state when laying the film. Compared with the original equipment, the horizontal movement speed of the film feeding unit 23 can be increased and the laying effect can be maintained, thus increasing the laying speed.
  • the film in this embodiment is set at a set angle ⁇ .
  • the angle range of ⁇ is 30 degrees (°) to 60 degrees (°). The angle can be flexibly set according to needs to ensure the film The end is accurately transported to the surface of the board.
  • the film feeding unit 23 includes a lower driving roller 231 that is rotatably arranged on the first support plate 22 , a second driving member 232 that drives the lower driving roller 231 to perform rotational movement, and is implemented in cooperation with the lower driving roller 231
  • the upper pressing roller 233 for film conveying.
  • the film input side formed by the upper pressing roller 233 and the lower driving roller 231 is provided with a second support plate 234 for dragging the film to ensure that the film can be accurately and effectively input to the upper pressing roller 233 and the lower driving roller. between 231.
  • both ends of the upper holding roller 233 are rotatably arranged on a pair of third support plates 236 through bearings, and the first end of each third support plate 236 is connected at A hinge seat 237 is provided and the second end of the third support plate 236 is hinged with the movable end of the first cylinder 235 .
  • the fixed side of the first cylinder 235 is hingedly provided on the first support plate 22 .
  • the upper holding roller 233 can rotate and swing around the support axis formed by the hinge seat 237, thereby achieving close contact and separation from the lower driving roller 231, which facilitates film threading and maintenance. work; and this structure eliminates the slide rail structure in related technologies, and the overall structure is simpler.
  • the circumferential surface of the upper holding roller 233 is symmetrically provided with two-way thread grooves to prevent film deflection.
  • the cutting unit 24 includes a third driving member 241 fixed on the first supporting plate 22, a fourth supporting plate 242 moved up and down by the third driving member 241, an upper cutting knife 240 fixed on the fourth supporting plate 242, and The lower cutting knife 243 is below the upper cutting knife 240 and cooperates with it for cutting.
  • the output side of the cutting unit 24 is provided with a fifth support plate 244 that holds the film. Both ends of the fifth support plate 244 are fixedly connected below the fourth support plate 242 through connectors.
  • the support plane of the fifth support plate 244 is arranged parallel to the feeding direction of the film feeding unit 23 .
  • the fourth support plate 242 is also provided with a plurality of compression nozzles 245 that compress the film close to the cutting position.
  • the compression nozzles 245 are connected to the air source. During cutting, the film is pressed, and the film is cut. After cutting, blow air toward the film by pressing the suction nozzle 245 to prevent the film from sticking to the knife.
  • the cutting unit 24 may also adopt a rolling cutting method.
  • the cutting unit 24 in this embodiment adopts a line cutting method.
  • a plurality of support rollers 13 are provided on the left and right sides of the conveying unit 11.
  • the support rollers 13 are arranged to support the edge of the plate.
  • the tail end pressing unit 25 includes a second cylinder 251, a pressure plate 252 driven by the second cylinder 251 to move up and down, and a lower support block 253 located below the pressure plate 252 and supporting the plate.
  • the pressure plate 252 and the lower support block 253 are made of plastic or rubber to avoid hard contact with the plate.
  • the tail end pressing unit 25 is fixed on the plate positioning unit 12, for example, fixed on one side positioning module of the left and right positioning modules 122, and moves with the side positioning module to above the edge of the plate. , and then start the second cylinder 251 to drive the pressing plate 252 to press the film on the plate.
  • the tail end pressing unit 25 can also be fixedly arranged above the plate conveying mechanism 1. After the plate is conveyed in place and the surroundings are positioned, the film is pressed downward from above.
  • the film feeding mechanism 3 can be a film feeding mechanism in the related art, and can be a single-axis feeding mechanism or a bi-axial feeding mechanism, such as a film spreading machine disclosed in the patent publication number CN114132778A.
  • the buffer mechanism 4 includes a plurality of fixed roller groups with fixed height positions, a pair of movable rollers 41 with adjustable height positions, and a fourth driving member 42 that drives the pair of movable rollers 41 to move up and down.
  • the fixed roller group includes a first roller 43 located in the middle and a pair of second rollers 44 located on both sides of the first roller 43 . Seen along the film conveying direction, one of the movable rollers 41 is located between the first roller 43 and one of the second rollers 44, and the other movable roller 41 is located between the first roller 43 and the other second roller 44. between. Both ends of the movable roller 41 are fixedly arranged on two vertically arranged transmission belts 45 for circular transmission.
  • the fourth driving member 42 can drive the transmission belt 45 for vertical circular transmission, thereby driving the movable roller 41 to realize automatic height position adjustment. adjust.
  • the film is sequentially wound from the output end of the film feeding mechanism 3 through the second roller 44A, the movable roller 41A, the first roller 43, the movable roller 41B, and the second roller 44B, and then is output to the punching mechanism 5 .
  • the punching mechanism 5 can adopt the EVA/TPT punching mechanism in the related art, such as the "round hole punching mechanism" in an EVA cutting and laying machine disclosed in the patent publication number CN112390048A.
  • This embodiment also provides a method for efficient and automatic laying of thin films of photovoltaic modules, which includes the following steps:
  • S1 Use the film feeding unit 23 to clamp the end of the film and move it from one side of the plate to the other opposite side.
  • the film feeding unit 23 clamps the end of the film and pulls the film from one side of the plate to the other opposite side. Maintain a set height distance from the board; in order to improve the lamination efficiency, it is recommended to set the film pulling action before the board is input in place, or at the same time as the board input, to avoid waiting for the film to be pulled after the board is in place, and to reduce ineffective waiting time;
  • the film feeding unit 23 continues to output the film of the set length at a set angle with the surface of the plate, so that the end edge of the film extends obliquely downward from the edge of the plate;
  • the film feeding unit 23 moves backward horizontally by a set distance so that the end edge of the film can cover the surface of the board and move to the initial position of film laying;
  • the film feeding unit 23 Drive the film feeding unit 23 to return to the initial side of the plate, and maintain the film feeding state during the return, and make the film feeding speed the same as the return speed of the film feeding unit 23; in this embodiment, the film is relative to the film feeding unit
  • the relative displacement between the upper holding roller 233 and the lower driving roller 231 in 23 is in the feeding state; during the film laying process, the film feeding state is maintained.
  • the film feeding unit 23 has a clamping force on the film.
  • the film support mechanism in the original setting is laid by utilizing the film's own weight to sag, which can effectively prevent the film from sagging too much under its own gravity and causing wrinkles; on the other hand, the film feeding unit 23 has a conveying force on the film.
  • Film pulling strictly ensure that the film is laid in a line laying method, not a surface laying method, thereby effectively avoiding the occurrence of bubbles and improving the laying effect; finally, the dynamic feeding action of the film is used to offset the pulling of the film when the film feeding unit 23 returns by itself function, which can effectively prevent the film from being damaged;
  • the film feeding unit 23 and the cutting unit 24 are jointly disposed on the first support plate 22 and are driven by a first driving member 21 to move horizontally.
  • the film feeding unit 23 and the cutting unit 24 can also be provided separately.
  • the film feeding unit 23 is driven by the first driving member 21 to move horizontally above the plate conveying mechanism 1, and the cutting unit 24 is provided on Below the plate conveying plane and located at the initial side of the film pulling, after the film laying is completed, the film feeding unit 23 returns to the rear side of the cutting unit 24 (in terms of the film feeding direction, the forward direction of conveying is the front side, The reverse direction is the rear side), and then the cutting unit 24 rises upward to cut the film.
  • This embodiment provides a high-efficiency automatic film laying device and laying method.
  • the film feeding unit 23 and the cutting unit 24 are integrated and arranged on a movable plate, and are driven by a horizontal drive mechanism to realize horizontal transfer.
  • the film feeding unit 23 realizes the film on the one hand.
  • the film support mechanism in the original equipment is omitted, and the horizontal transfer driving mechanism of the film support mechanism is also omitted;
  • the film feeding unit 23 is set on the transfer mechanism to cooperate with the film laying, using
  • the clamping force of the film feeding unit 23 on the film cooperates with the feeding action and is combined with the reverse horizontal movement of the film feeding unit 23 itself to complete the film laying, greatly improving the film laying effect;
  • the entire laying process eliminates the need for the original equipment
  • the film support action, the transfer action of the film support mechanism, and the separate return and transfer action of the pulling mechanism improve the laying efficiency; and the use of the film feeding unit 23 for the laying action makes the laying speed faster.

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Abstract

本申请公开了一种薄膜高效自动铺设装置及铺设方法，该装置包括板材输送机构、设置在所述板材输送机构上方的薄膜铺设机构；所述薄膜铺设机构包括第一驱动件、受所述第一驱动件驱动进行水平移动的第一支撑板、设置在所述第一支撑板上的薄膜送料单元与裁切单元、以及将薄膜尾端压紧在板材表面上的尾端压紧单元，所述裁切单元位于所述薄膜送料单元的薄膜输出侧。

Description

薄膜高效自动铺设装置及铺设方法
本公开要求在2022年4月28日提交中国专利局、申请号为202210463603.X的中国专利申请的优先权，以上申请的全部内容通过引用结合在本申请中。
技术领域
本申请属于覆膜设备技术领域，例如涉及一种薄膜高效自动铺设装置及铺设方法。
背景技术
在节能环保的大环境下，新能源的开发应用越来越广泛，需求量也越来越大。其中太阳能发电得到了迅猛的发展，因此对于太阳能组件的需求也迅速增长。太阳能组件一般是由一块或两块钢化玻璃、乙烯-乙酸乙烯共聚物(Ethyl Vinyl Acetate，EVA)胶膜和太阳能电池硅片，经过层压机高温层压组成复合层，电池片之间由导线串、并联汇集到引线端所形成的光伏电池组件。在其生产过程中，有一道工序是EVA薄膜或聚氟乙烯结构(Tedlar/PET/Tedlar，TPT)薄膜的敷设，由于光伏组件的生产大多数工序都实现了自动化，其整个组装生产线也具有自动化流水线，因此，对于光伏组件的生产节拍要求较高，以满足高效的流水线生产。
相关技术中，对于EVA或TPT薄膜的自动铺设机一般都包括薄膜供料、薄膜送料、薄膜冲孔、薄膜裁切、薄膜拉料以及薄膜支撑铺设这几个模组，如专利CN112850309A公开的一种用于光伏组件所使用的EVA的在线裁切铺设机、专利CN109103287A公开的一种薄膜裁切、铺设一体机、CN113844930A公开的双轴自动上料在线裁切冲孔敷设一体机等，相关技术中的这些光伏组件薄膜自动铺设机构，基本上都是利用拉料模组将薄膜拉至末端合适位置，在拉料过程中，利用薄膜支撑铺设模组将薄膜底部拖住，防止薄膜中间下垂与玻璃板或电池板发生摩擦拖拽；利用拉料模组夹紧薄膜的尾端并保持住，然后利用薄膜支撑铺设模组回退将薄膜敷设在玻璃板或电池板上，然后再利用裁切模组切断薄膜。这些机构存在以下缺点：
1)薄膜送料模组和薄膜裁切模组基板上都是固定设置的，拉料模组单独设置在一个移载机构上进行拉料，还要配合薄膜支撑铺设模组才能较好的实现薄 膜敷设，整体结构较为复杂，部件模组较多；
2)由于薄膜一般都是自由搭落在薄膜支撑铺设模组上，在铺设时，对薄膜的展平效果有限，使得铺设效果不佳；
3)整个铺设过程的机构动作较多，铺设效率不够高。
发明内容
本申请提供了一种薄膜高效自动铺设装置及铺设方法，结构模组少，铺设效果好且铺设效率高。
第一方面，本申请实施例提供了一种薄膜高效自动铺设装置，包括板材输送机构、设置在所述板材输送机构上方的薄膜铺设机构；所述薄膜铺设机构包括第一驱动件、受所述第一驱动件驱动进行水平移动的第一支撑板、设置在所述第一支撑板上的薄膜送料单元与裁切单元、以及将薄膜尾端压紧在板材表面上的尾端压紧单元，所述裁切单元位于所述薄膜送料单元的薄膜输出侧。
第二方面，本申请实施例提供了一种薄膜高效自动铺设方法，包括：
利用一薄膜送料单元夹持薄膜端部从板材的一侧移动至另一相对侧，所述薄膜与所述板材之间保持设定的高度距离；所述薄膜送料单元的送料方向与水平面之间呈设定夹角设置；
在薄膜拉料到位之后，所述薄膜送料单元继续输出设定长度的薄膜，使得所述薄膜的端部边缘倾斜向下伸出所述板材的边缘；
所述薄膜送料单元水平向后移动设定距离，使得所述薄膜的端部边缘贴附所述板材表面移动至薄膜敷设的初始位置；
利用一尾端压紧单元向下压紧所述薄膜的端部，使得所述薄膜的端部紧紧的贴覆在所述板材表面上并保持住；
驱动所述薄膜送料单元水平移动返回至所述板材的初始侧，且在返回途中，保持薄膜送料状态，并使得薄膜送料速度与所述薄膜送料单元的返回速度相同；
在所述薄膜送料单元返回至所述板材的初始侧之后，利用一裁切单元切断所述薄膜送料单元输出侧的薄膜，完成薄膜的铺设。
附图说明
图1为本申请实施例的立体结构示意图；
图2为本申请实施例的俯视结构示意图；
图3为本申请实施例中薄膜铺设机构的结构示意图；
图4为本申请实施例中薄膜送料单元与裁切单元的侧视结构示意图；
图5为本申请实施例中薄膜送料单元的结构示意图；
图6为本申请实施例中裁切单元的结构示意图；
图7为本申请实施例中裁切单元的另一角度结构示意图；
图8为本申请实施例中板材输送机构的结构示意图；
图9为本申请实施例中缓存机构的结构示意图；
图10为本申请实施例中薄膜铺设时的部分状态结构示意图；
图中数字表示：
100、薄膜高效自动铺设装置；
1、板材输送机构；11、输送单元；12、板材定位单元；121、前后定位模组；122、左右定位模组；13、支撑滚轴；
2、薄膜铺设机构；21、第一驱动件；22、第一支撑板；23、薄膜送料单元；231、下驱动滚轴；232、第二驱动件；233、上压持滚轴；234、第二支撑板；235、第一气缸；236、第三支撑板；237、铰接座；238、薄膜输出侧；24、裁切单元；240、上切刀；241、第三驱动件；242、第四支撑板；243、下切刀；244、第五支撑板；245、压紧吸嘴；25、尾端压紧单元；251、第二气缸；252、压板；253、下支撑块；
3、薄膜供料机构；
4、缓存机构；41、活动滚轴；42、第四驱动件；43、第一滚轴；44、第二滚轴；45、传动带；
5、冲孔机构。
具体实施方式
请参照图1-图10，本实施例为一种薄膜高效自动铺设装置100，其包括板材输送机构1、设置在板材输送机构1上方的薄膜铺设机构2、为薄膜铺设机构2供料的薄膜供料机构3、以及设置在薄膜供料机构3与薄膜铺设机构2的缓存机构4与冲孔机构5。
本实施例中，板材输送机构1的输送方向与薄膜铺设机构2的铺设方向垂直设置。在其他实施例中，板材输送机构1的输送方向也可以与薄膜铺设机构2的铺设方向平行设置。
板材输送机构1包括输送单元11、对输送单元11上板材的四周进行定位的板材定位单元12，板材定位单元12包括前后定位模组121与左右定位模组122。
在其他实施例中，板材输送机构1也可以采用相关技术中具有板材四周定位功能的输送装置，如专利公开号为CN112390048A公开的一种EVA裁剪铺设机中的“伺服输送归正组件”、或专利公开号为CN215755272U公开的一种高效太阳能大组件竖直码垛机设备中的“输送线和夹紧规正组件”构成的输送机构等。
薄膜铺设机构2包括第一驱动件21、受第一驱动件21驱动垂直于板材输送机构1输送方向运动的第一支撑板22、设置在第一支撑板22上的薄膜送料单元23与裁切单元24、以及位于板材输送机构1一侧夹持薄膜尾端的尾端压紧单元25，裁切单元24位于薄膜送料单元23的薄膜输出侧238。
在铺设薄膜时，薄膜供料机构3输出的薄膜穿过薄膜送料单元23和裁切单元24，由薄膜送料单元23夹持薄膜的端部然后在第一驱动件21的移载驱动下从板材的一侧移动至另一相对侧，然后由薄膜送料单元23输出设定长度的薄膜，使薄膜的端部伸入至尾端压紧单元25的夹持范围内，然后由尾端压紧单元25夹紧薄膜的端部，薄膜送料单元23和裁切单元24再在第一驱动件21的移载驱动下返回至板材初始侧，并通过裁切单元24切断薄膜，完成薄膜的铺设。
薄膜送料单元23和裁切单元24在从板材一侧移动至另一侧的过程中，为了防止薄膜在板材表面造成拖拽和摩擦，本实施例中，薄膜铺设机构2的薄膜输出侧238与板材之间存在设定距离的高度差。为了保障薄膜的铺设效果，本实施例中的尾端压紧单元25是直接将薄膜压紧在板材上，这里的板材可以是玻璃板或电池板等，通过将薄膜直接压紧在板材上，再配合薄膜送料单元23从板材的另一侧返回至初始侧的折返移动，薄膜进行铺设的位置由于受到薄膜送料单元23的输送递给作用力，使得贴覆位置的薄膜是受到一定的压持力贴覆到板材上的，从而可以大大提高薄膜铺设的效果；且利用薄膜送料单元23严格控制薄膜的输送，使得薄膜能够保持完全的展平状态，完成板材表面的薄膜铺设。薄膜送料单元23在铺设薄膜时还保持送料状态，相比于原有设备，薄膜送料单元23的水平移动速度可以得到提升，且还能够保持铺设的效果，因此，提高了铺设速度。
参见图4，为了保障薄膜端部能够被输送至尾端压紧单元25的夹持范围内，且能够更好的被尾端压紧单元25夹持贴紧板材表面，本实施例中的薄膜送料单元23的送料方向T与水平面L之间呈设定夹角α设置，例如α的角度范围为30度 (°)～60度(°)，该夹角可根据需要灵活设置，以保障薄膜的端部被精准的输送至板材表面。
本实施例中，薄膜送料单元23包括旋转设置在第一支撑板22上的下驱动滚轴231、驱动下驱动滚轴231进行旋转运动的第二驱动件232、与下驱动滚轴231配合实现薄膜输送的上压持滚轴233。上压持滚轴233与下驱动滚轴231形成的薄膜输入侧设置有第二支撑板234，用于拖住薄膜，保障薄膜能够精准的有效的输入至上压持滚轴233与下驱动滚轴231之间。当薄膜换料时或薄膜送料单元23进行维修检查时，为了方便操作，上压持滚轴233受一第一气缸235驱动进行贴紧或远离下驱动滚轴231的运动，以控制上压持滚轴233对下驱动滚轴231压持力的施加与释放。为了简化薄膜送料单元23的结构，本实施例中，上压持滚轴233的两端通过轴承旋转设置在一对第三支撑板236上，每个第三支撑板236的第一端交接在一铰接座237上且第三支撑板236的第二端与第一气缸235的活动端铰接。第一气缸235的固定侧铰接设置在第一支撑板22上。通过第一气缸235的驱动，使得上压持滚轴233可以绕着铰接座237构成的支撑轴线进行旋转摆动，进而实现与下驱动滚轴231紧贴与分开动作，方便薄膜穿料和维修保养工作；且该结构省去了相关技术中的滑轨结构，整体结构更加简洁。本实施例中，上压持滚轴233的圆周表面上对称设置有防止薄膜偏斜的双向螺纹槽。
裁切单元24包括固定在第一支撑板22上的第三驱动件241、受第三驱动件241上下运动的第四支撑板242、固定在第四支撑板242上的上切刀240、位于上切刀240下方且与其配合裁切的下切刀243。裁切单元24的输出侧设置有拖住薄膜的第五支撑板244，第五支撑板244的两端通过连接件固定连接在第四支撑板242的下方。第五支撑板244的支撑平面与薄膜送料单元23的送料方向平行设置。为了保障裁切效果，第四支撑板242上还设置有压紧薄膜靠近裁切位置的多个压紧吸嘴245，压紧吸嘴245连通气源，在裁切时，压紧薄膜，裁切完后，通过压紧吸嘴245朝薄膜吹气，防止薄膜粘刀。
在其他实施例中，裁切单元24也可以采用滚切方式，例如，本实施例中的裁切单元24采用线切方式。
本实施例中，输送单元11的左右两侧设置有多个支撑滚轴13，支撑滚轴13设置为支撑住板材的边缘，在尾端压紧单元25下压压紧薄膜时，为板材边缘提供支撑，防止压坏板材。尾端压紧单元25包括第二气缸251、受第二气缸251驱动进行上下运动的压板252、位于压板252下方且支撑板材的下支撑块253。压板252与下支撑块253采用塑胶或橡胶材质，避免与板材硬性接触。
本实施例中，尾端压紧单元25固定在板材定位单元12上，例如固定在左右定位模组122中的一侧定位模组上，随着该一侧定位模组一起移动至板材边缘上方，然后启动第二气缸251，驱动压板252压紧板材上的薄膜。在其他实施例中，尾端压紧单元25也可以固定设置在板材输送机构1的上方，当板材输送到位后，且四周定位好后，从上方向下压紧薄膜。
薄膜供料机构3可以采用相关技术中的薄膜供料机构，可以是单轴供料机构，也可以是双轴供料机构，如专利公开号为CN114132778A公开的一种薄膜展料机。
缓存机构4包括高度位置固定的多个固定滚轴组、以及高度位置能够调节的一对活动滚轴41、驱动一对活动滚轴41上下运动的第四驱动件42。所述固定滚轴组包括位于中间的第一滚轴43、位于第一滚轴43两侧的一对第二滚轴44。沿薄膜输送方向看，其中一个活动滚轴41位于第一滚轴43与其中一个第二滚轴44之间，另一个活动滚轴41位于第一滚轴43与另一个第二滚轴44之间。活动滚轴41的两端固定设置在两条竖向设置的循环传动的传动带45上，第四驱动件42可以驱动传动带45进行竖向的循环传动，进而带动活动滚轴41实现高度位置的自动调节。薄膜从薄膜供料机构3的输出端依次绕设经过第二滚轴44A、活动滚轴41A、第一滚轴43、活动滚轴41B、第二滚轴44B，然后输出至冲孔机构5处。
冲孔机构5可采用相关技术中的EVA/TPT冲孔机构，如专利公开号为CN112390048A公开的一种EVA裁剪铺设机中的“冲圆孔机构”。
本实施例还提供了一种光伏组件的薄膜高效自动铺设方法，包括以下步骤：
S1)利用薄膜送料单元23夹持薄膜的端部从板材的一侧移动至另一相对侧，例如，薄膜送料单元23夹持薄膜的端部从板材的一侧拉动至另一相对侧，薄膜与板材之间保持设定的高度距离；为了提高覆膜效率，拉膜动作建议设置在板材输入到位之前，或与板材输入同时进行，避免出现板材到位后等待拉膜，减少无效等待时间；
S2)在薄膜拉料到位之后，薄膜送料单元23以与板材表面呈设定夹角继续输出设定长度的薄膜，使得薄膜的端部边缘倾斜向下伸出板材的边缘；
S3)薄膜送料单元23水平向后移动设定距离，使得薄膜的端部边缘能够贴覆板材表面移动至薄膜敷设的初始位置；
S4)利用尾端压紧单元25向下压紧薄膜的端部，使得薄膜的端部能够紧紧的贴覆在板材表面上且保持住；
S5)驱动薄膜送料单元23返回至板材的初始侧，且在返回途中，保持薄膜送料状态，并使得薄膜送料速度与薄膜送料单元23的返回速度相同；本实施例中，薄膜相对于薄膜送料单元23中的上压持滚轴233与下驱动滚轴231具有相对位移则为送料状态；在薄膜铺设过程中，保持薄膜送料状态，一方面薄膜送料单元23对薄膜具有夹持作用力，相比于原有设置中的薄膜支撑机构利用薄膜自重下垂进行的铺设，能够有效的避免薄膜在自身重力作用下下垂太多造成褶皱；另一方面，薄膜送料单元23对薄膜具有输送作用力，在薄膜粘附板材表面时，能够对薄膜沿其自身物理曲率方向形成一定的挤压力，相比于原有设置中的薄膜支撑机构利用薄膜自重下垂进行的铺设，大大提高了薄膜与板材表面的贴附力，进而提高了铺设效果；还有一方面，利用薄膜送料单元23严格控制薄膜的输出速度与输送长度，可以保障薄膜处于完全的展平状态，既不会出现薄膜褶皱，也不会出现薄膜拉扯，严格保障薄膜的铺设是线铺设方式，而非面铺设方 式，进而有效的避免气泡发生，提高敷设效果；最后利用薄膜的动态送料动作来抵消薄膜送料单元23自身返回时对薄膜的拉扯作用，能够有效的防止薄膜被拉坏；
S6)在薄膜送料单元23返回至板材的初始侧之后，利用裁切单元24切断薄膜送料单元23输出侧的薄膜，完成薄膜的铺设。
在该薄膜铺设方法中，为了方便设备布局，本实施例中，薄膜送料单元23与裁切单元24共同设置在第一支撑板22上，且受一第一驱动件21驱动实现水平移动。在其他实施例中，薄膜送料单元23与裁切单元24也可以单独设置，例如，薄膜送料单元23受第一驱动件21驱动在板材输送机构1上方进行水平移动，裁切单元24则设置在板材输送平面的下方且位于薄膜拉料的初始侧位置，在薄膜铺设完成后，薄膜送料单元23返回至裁切单元24的后侧(以薄膜送料方向而言，输送正向方向为前侧，反向方向为后侧)，然后裁切单元24向上升起对薄膜进行裁切。
本实施例一种薄膜高效自动铺设装置及铺设方法，将薄膜送料单元23与裁切单元24集成设置在一个活动板上，并受水平驱动机构实现水平移载，薄膜送料单元23一方面实现薄膜的送料，另一方面实现薄膜的拉料动作，省去了原有设备中额外设置的拉料机构；且利用薄膜送料单元23对薄膜的拉持作用力以及与板材表面的高度差设计，无需对薄膜底部进行支托，省去了原有设备中的薄膜支撑机构，也省去了薄膜支撑机构的水平移载驱动机构；将薄膜送料单元23设置在移载机构上配合进行薄膜铺设，利用薄膜送料单元23对薄膜的夹持作用力配合送料动作，并结合薄膜送料单元23自身的反向水平移动，进而完成薄膜铺设，大大提高了薄膜铺设效果；整个铺设过程省去了原有设备中薄膜支撑动作、薄膜支撑机构的移载动作以及拉料机构的单独返回移载动作，提高了铺设效率；且利用薄膜送料单元23进行铺设动作，使得铺设速度更快。

Claims (11)

  1. 一种薄膜高效自动铺设装置，包括板材输送机构(1)、设置在所述板材输送机构(1)上方的薄膜铺设机构(2)；其中，所述薄膜铺设机构(2)包括第一驱动件(21)、受所述第一驱动件(21)驱动进行水平移动的第一支撑板(22)、设置在所述第一支撑板(22)上的薄膜送料单元(23)与裁切单元(24)、以及将薄膜尾端压紧在板材表面上的尾端压紧单元(25)，所述裁切单元(24)位于所述薄膜送料单元(23)的薄膜输出侧(238)。
  2. 根据权利要求1所述的薄膜高效自动铺设装置，其中，所述薄膜铺设机构(2)的薄膜输出侧(238)与所述板材输送机构(1)上板材表面之间存在设定距离的高度差。
  3. 根据权利要求1或2所述的薄膜高效自动铺设装置，其中，所述薄膜送料单元(23)的送料方向T与水平面L之间呈设定夹角α设置。
  4. 根据权利要求1所述的薄膜高效自动铺设装置，其中，所述薄膜送料单元(23)包括旋转设置在所述第一支撑板(22)上的下驱动滚轴(231)、驱动所述下驱动滚轴(231)进行旋转运动的第二驱动件(232)、与所述下驱动滚轴(231)配合实现薄膜输送的上压持滚轴(233)。
  5. 根据权利要求4所述的薄膜高效自动铺设装置，其中，所述上压持滚轴(233)受一第一气缸(235)驱动进行贴紧或远离所述下驱动滚轴(231)的运动；所述上压持滚轴(233)的两端通过轴承旋转设置在一对第三支撑板(236)上，每个所述第三支撑板(236)的第一端交接在一铰接座(237)上且所述第三支撑板(236)的第二端与所述第一气缸(235)的活动端铰接。
  6. 根据权利要求1所述的薄膜高效自动铺设装置，其中，所述裁切单元(24)包括固定在所述第一支撑板(22)上的第三驱动件(241)、受所述第三驱动件 (241)驱动上下运动的第四支撑板(242)、固定在所述第四支撑板(242)上的上切刀(240)、位于所述上切刀(240)下方且与其配合裁切的下切刀(243)；所述裁切单元(24)的输出侧设置有拖住薄膜的第五支撑板(244)，所述第五支撑板(244)的两端通过连接件固定连接在所述第四支撑板(242)的下方；所述第五支撑板(244)的支撑平面与所述薄膜送料单元(23)的送料方向平行设置。
  7. 根据权利要求6所述的薄膜高效自动铺设装置，其中，所述第四支撑板(242)上设置有压紧薄膜靠近裁切位置的多个压紧吸嘴(245)，所述压紧吸嘴(245)连通气源。
  8. 根据权利要求1所述的薄膜高效自动铺设装置，所述薄膜高效自动铺设装置还包括为所述薄膜铺设机构(2)供料的薄膜供料机构(3)、设置在所述薄膜供料机构(3)与所述薄膜铺设机构(2)之间的缓存机构(4)与冲孔机构(5)。
  9. 根据权利要求1所述的薄膜高效自动铺设装置，其中，所述板材输送机构(1)包括输送单元(11)、对所述输送单元(11)上的板材四周进行定位的板材定位单元(12)，所述板材定位单元(12)包括前后定位模组(121)与左右定位模组(122)；
    所述尾端压紧单元(25)包括第二气缸(251)、受所述第二气缸(251)驱动进行上下运动的压板(252)、位于所述压板(252)下方且支撑板材的下支撑块(253)；所述尾端压紧单元(25)固定在所述左右定位模组(122)的一侧的定位模组上，随着该一侧的定位模组一起移动至板材边缘上方，然后所述第二气缸(251)驱动所述压板(252)向下压紧板材上的薄膜。
  10. 一种薄膜高效自动铺设方法，包括：
    利用一薄膜送料单元夹持薄膜的端部从板材的一侧移动至另一相对侧，所述薄膜与所述板材之间保持设定的高度距离；所述薄膜送料单元的送料方向与水平面之间呈设定夹角设置；
    在薄膜拉料到位之后，所述薄膜送料单元继续输出设定长度的薄膜，使得所述薄膜的端部边缘倾斜向下伸出所述板材的边缘；
    所述薄膜送料单元水平向后移动设定距离，使得所述薄膜的端部边缘贴附所述板材表面移动至薄膜敷设的初始位置；
    利用一尾端压紧单元向下压紧所述薄膜的端部，使得所述薄膜的端部紧紧的贴覆在所述板材表面上并保持住；
    驱动所述薄膜送料单元水平移动返回至所述板材的初始侧，且在返回途中，保持薄膜送料状态，并使得薄膜送料速度与所述薄膜送料单元的返回速度相同；
    在所述薄膜送料单元返回至所述板材的初始侧之后，利用一裁切单元切断所述薄膜送料单元输出侧的薄膜，完成薄膜的铺设。
  11. 根据权利要求10所述的薄膜高效自动铺设方法，其中，所述薄膜送料单元与所述裁切单元共同设置在一个第一支撑板上，所述第一支撑板受一第一驱动件驱动实现水平移动。
PCT/CN2022/138619 2022-04-28 2022-12-13 薄膜高效自动铺设装置及铺设方法 WO2023207131A1 (zh)

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