Patent ID: 12224371

REFERENCE LIST

100high-speed layout device for photovoltaic module101photovoltaic module1module input unit11second avoidance gap2module output unit21first avoidance gap3tray transfer unit31first support plate32driving member33cylinder34support frame group341second support plate342support rod343support upright rod344support towing rod4layout transfer unit

DETAILED DESCRIPTION

Embodiment One

This embodiment provides a high-speed layout method. The method includes that: a module input unit1and a module output unit2are arranged vertically, that is, a convey direction of the module input unit1is perpendicular to a convey direction of the module output unit2, where the module input unit1is configured to convey a photovoltaic module in a first direction, the module output unit2is configured to convey the photovoltaic module in a second direction, and the first direction is perpendicular to the second direction; a tray transfer unit3is configured, where the tray transfer unit3is configured to be capable of extending into a position below the module input unit1to lift the photovoltaic module upwards and lift above the module input unit1, is configured to be capable of lifting the photovoltaic module and moving in the second direction in a space above the module output unit2according to a layout requirement, and is configured to be capable of descending and embedding below the module output unit2and returning to the position below the module input unit1in the second direction: one or two layout transfer units4are configured, where the one or two layout transfer units4are configured to be capable of absorbing battery strings and placing the battery strings on the photovoltaic module according to the layout requirement; and the battery strings on the photovoltaic module are divided into a first row of battery strings, a middle row of battery strings, and a last row of battery strings, where a layout of the middle row of battery strings is performed on the tray transfer unit3, a layout of the first row of battery strings is performed on the module input unit1or the tray transfer unit3, a layout of the last row of battery strings is performed on the tray transfer unit3or the module output unit2, and the layout of the first row of battery strings and the layout of the last row of battery strings are not all performed on the tray transfer unit3, that is, the layout of the first row of battery strings and the layout of the last row of battery strings are performed on different units: in a process of performing the layout of the first row of battery strings or the layout of the last row of battery strings, the tray transfer unit3completes a movement operation returned from below the module output unit2to below the module input unit1; and in a time period in which the photovoltaic module on the module input unit1is lifted by the tray transfer unit3until the layout of the last row of battery strings on the photovoltaic module is finished, operations of input a next photovoltaic module in place and position correction of the next photovoltaic module on the module input unit1are completed.

According to the above-described method, this embodiment provides an embodiment of the high-speed layout method. In this embodiment, the layout of the first row of battery strings is performed on the module input unit1, the layout of the last row of battery strings is performed on the module output unit2, and the layout of the middle row of battery strings is performed on the tray transfer unit3. The method specifically includes the following steps.

In S1, the photovoltaic module101is conveyed in place in the first direction from one end of the module input unit1, and a position of the photovoltaic module101on the module input unit1is corrected.

In S2, the layout transfer unit4absorbs qualified battery strings and places absorbed qualified battery strings on the photovoltaic module to complete the layout of the first row of battery strings.

In S3, in a process of performing the S1 and the S2, the tray transfer unit3extends into the position below the module input unit1and is in place.

In S4, after the S2 is finished, the tray transfer unit3lifts the photovoltaic module upwards and lifts above a set height of the module input unit1, where the set height is greater than a thickness of the photovoltaic module, so that a next photovoltaic module can smoothly enter the module input unit1.

In S5, the tray transfer unit3supports the photovoltaic module and moves the photovoltaic module a set step distance in the second direction, where the set step distance is a width of one battery slice.

In S6, the layout transfer unit4absorbs qualified battery strings and places absorbed qualified battery strings on the photovoltaic module to complete a layout of a next row of battery strings.

In S7, the S5 and the S6 are repeated for multiple times to complete the layout of the middle row of battery strings, and when the layout of the last row of battery strings is to be performed, the S5 and the S6 are stopped repeating.

In S8, the tray transfer unit3supports the photovoltaic module and lowers the photovoltaic module, and places the photovoltaic module on the module output unit2to complete a transferring of the photovoltaic module. After the photovoltaic module is placed on the module output unit2, the input of a next photovoltaic module is not influenced.

The expression “not influence the input of the next photovoltaic module” here may be either a non-influence in a horizontal plane or a non-influence in the height. For example, in an embodiment, a height difference exists between a conveyance plane of the module input unit1and a conveyance plane of the module output unit2, and the height difference is greater than the thickness of the photovoltaic module. In this structure design, the photovoltaic module placed on the module output unit2does not collide and interfere with a next photovoltaic module input into the module input unit1. The photovoltaic module on the module output unit2and the photovoltaic module on the module input unit1are allowed to have an overlapping portion in a height space. In this way, a horizontal spacing between the module input unit1and the module output unit2can be shortened, so that a size of a layout machine in the second direction is reduced, and thus space is saved. After the layout of the last row of battery strings on the photovoltaic module is completed, the photovoltaic module is output by the module output unit2, to eliminate the overlapping of two photovoltaic modules in the height space and provide an avoidance space for the rising of the next photovoltaic module. The photovoltaic module on the module output unit2and the photovoltaic module on the module input unit1may also have no overlapping portion in the height space.

In another embodiment, the conveyance plane of the module input unit1is flush with the conveyance plane of the module output unit2, and the photovoltaic module on the module output unit2and the photovoltaic module on the module input unit1do not interfere with each other since they have a gap on the horizontal plane.

In S9, the layout transfer unit4absorbs qualified battery strings and places absorbed qualified battery strings on the photovoltaic module to complete the layout of the last row of battery strings, and then the module output unit2outputs the photovoltaic module whose layout is finished.

In S10, in a process of performing the S5 to the S9, an input of the next photovoltaic module and a position correction of the next photovoltaic module on the module input unit1are completed, that is, the next photovoltaic module is input onto the module input unit1and is in place, and a position of the next photovoltaic module on the module input unit1is corrected.

In S11, after the S9 is finished, input of the next photovoltaic module in place and position correction of the next photovoltaic module are completed, and the layout transfer unit4absorbs qualified battery strings and places absorbed qualified battery strings on the next photovoltaic module to complete a layout of a first row of battery strings on the next photovoltaic module, so that the continuous layout operation is achieved, and the tact time consumed in preparation of the layout of the next photovoltaic module is eliminated. The main control time of the whole layout operation mainly depends on the time consumed by operations of the battery string absorption of the layout transfer unit4, the lead cutting of the layout transfer unit4, the layout and transfer of the layout transfer unit4, and the layout operation will not be stopped because of waiting for the input of the next photovoltaic module, the position correction of the next photovoltaic module, and the reset of the tray transfer unit3, thereby improving the layout efficiency.

In S12, in a process of performing the S9 and the S11, the tray transfer unit3descends to a position below the module output unit2and returns to the position below the module input unit1and is in place.

In the above-described layout step, two sets of layout transfer units4may be provided to pick up two rows of battery strings at the same time, so that performing layout operation once can complete a layout of two rows of battery strings. Compared with a single robot layout in the related art, the efficiency of the layout can be more than doubled.

In order to implement an operation requirement of the tray transfer unit3, that is, tray transfer unit3lifts the photovoltaic module on the module input unit1upwards, moves according to the set step distance in the second direction in the space above the module output unit2, places the photovoltaic module on the module output unit2, and then lowers to the position below the module output unit2and moves back to the position below the module input unit1in the second direction, the reasonable structure design is performed on the tray transfer unit3in this embodiment. Optionally, the tray transfer unit3includes a first support plate31, a driving member32that drives the first support plate31to move in the second direction, a cylinder33fixed on the first support plate31, and a support frame group34that is driven by the cylinder33to move up and down and that is used to support the photovoltaic module. The support frame group34is driven by the cylinder33to perform the position switching between a position above the module output unit2and a position below the module output unit2. The driving member32, the first support plate31and the cylinder33are all disposed below the module output unit2, so that the tray transfer unit3can be retracted to the position below the module output unit2and moves in the second direction to return to the position below the module input unit1.

In order that the support frame group34can extend into the position below the module input unit1to lift the photovoltaic module upwards and can move up and down in the module output unit2, the support frame group34includes a second support plate341that is driven by the cylinder33to move up and down, a support rod342that is fixed on the second support plate341and is parallel to the first direction, multiple support upright rods343disposed on the support rod342at intervals, and support towing rods344having first ends fixed on the support upright rods343and second ends extending horizontally parallel to the second direction: where a support towing rod of the support towing rods344is disposed on a top end of a respective support upright rod of the support upright rods343in an overhanging manner and extends in a direction towards the module input unit1. The module output unit2is provide with a first avoidance gap21penetrating in the second direction, and the first avoidance gap21is capable of accommodating a support upright rod343and a support towing rod344distributed in the first avoidance gap21, and the support rod342is located below the module output unit2.

As shown inFIG.2, a second avoidance gap11is formed on the module input unit1, and the second avoidance gap11is capable of allowing the support towing rod344to extend into the position below the module input unit1and is capable of allowing the support towing rod to move upwards above the module input unit1.

When the support upright rod343gets close to the module input unit1, the overhanging and extending support towing rod344may gradually extends into the module input unit1and extends to a position below the photovoltaic module. When the support rod344gets away from the module input unit1, the support towing rod344may gradually retracts into a conveyance section of the module output unit2, and the photovoltaic module may be placed on the conveyance plane of the module output unit2by moving up and down. The support frame group34may be driven by the driving member32to achieve the movement with equal step distance, thereby satisfying the layout and transfer requirement.

This embodiment further provides a high-speed layout device100for a photovoltaic module. The high-speed layout device100for the photovoltaic module includes the module input unit1, the module output unit2, the tray transfer unit3, and the layout loading unit4that satisfy the layout requirement in the above-described layout method.

Embodiment Two

This embodiment provides another embodiment of a high-speed layout method. In this embodiment, a layout of the first row of battery strings is performed on the module input unit1, and a layout of the middle row of battery strings and a layout of the last row of battery strings are performed on the tray transfer unit3. The method specifically includes the following steps.

In S1, the photovoltaic module101is conveyed in place in the first direction from one end of the module input unit1, and a position of the photovoltaic module101on the module input unit1is corrected.

In S2, the layout transfer unit4absorbs qualified battery strings and places absorbed qualified battery string on the photovoltaic module to complete the layout of the first row of battery strings.

In S3, in a process of performing the S1 and the S2, the tray transfer unit3extends into a position below the module input unit1and is in place.

In S4, after the S2 is finished, the tray transfer unit3lifts the photovoltaic module upwards and lifts above a set height of the module input unit1, where the set height is greater than a thickness of the photovoltaic module, so that a next photovoltaic module can smoothly enter.

In S5, the tray transfer unit3supports the photovoltaic module and moves the photovoltaic module a set step distance in the second direction, where the set step distance is a width of one battery slice.

In S6, the layout transfer unit4absorbs qualified battery strings and places absorbed qualified battery strings on the photovoltaic module to complete a layout of a next row of battery strings.

In S7, the S5 and the S6 are repeated for multiple times to complete the layout of the middle row of battery strings and the layout of the last row of battery strings.

In S8, the tray transfer unit3supports the photovoltaic module and lowers the photovoltaic module, and places the photovoltaic module on the module output unit2to complete a transferring of the photovoltaic module.

In S9, the module output unit2outputs the photovoltaic module whose layout is finished.

In S10, in a process of performing the S5 to the S9, an input of the next photovoltaic module and a position correction of the next photovoltaic module on the module input unit1are completed, that is, the next photovoltaic module is input onto the module input unit1and is in place, and a position of the next photovoltaic module on the module input unit1is corrected.

In S11, after the S9 is finished, input of the next photovoltaic module in place and position correction of the next photovoltaic module are completed, and the layout transfer unit4absorbs qualified battery strings and places absorbed qualified battery strings on the next photovoltaic module, to complete a layout of a first row of battery strings on the next photovoltaic module and thus achieve the continuous layout operation.

In S12, in a process of performing the S9 and the S11, the tray transfer unit3descends to a position below the module output unit2and returns to the position below the module input unit1and is in place.

Embodiment Three

This embodiment provides still another embodiment of a high-speed layout method. In this embodiment, both a layout of the first row of battery strings and a layout of the middle row of battery strings are performed on the tray transfer unit3, and a layout of the last row of battery strings is performed on the module output unit2. The method specifically includes the following steps.

In S1, the photovoltaic module101is conveyed in place in the first direction from one end of the module input unit1, and a position of the photovoltaic module101on the module input unit1is corrected.

In S2, in a process of performing the S1, the tray transfer unit3extends to a position below the module input unit1and is in place.

In S3, the tray transfer unit3lifts the photovoltaic module upwards and lifts above a set height of the module input unit1, where the set height is greater than a thickness of the photovoltaic module, so that a next photovoltaic module can smoothly enter.

In S4, the layout transfer unit4absorbs qualified battery strings and places absorbed qualified battery strings on the photovoltaic module to complete the layout of the first row of battery strings, where before the layout of the first rows of battery strings is performed, the tray transfer unit3may move a distance in the second direction to a preset layout position after the tray transfer unit3moves the photovoltaic module to a preset height.

In S5, the tray transfer unit3supports the photovoltaic module and moves the photovoltaic module a set step distance in the second direction, where the set step distance is a width of one battery slice.

In S6, the layout transfer unit4absorbs qualified battery strings and places absorbed qualified battery strings on the photovoltaic module to complete a layout of a next row of battery strings.

In S7, the S5 and the S6 are repeated for multiple times to complete the layout of the middle row of battery strings, and when the layout of the last row of battery string is to be performed, the S5 and the S6 are stopped repeating.

In S8, the tray transfer unit3supports the photovoltaic module and lowers the photovoltaic module, and places the photovoltaic module on the module output unit2to complete a transferring of the photovoltaic module.

In S9, the layout transfer unit4absorbs qualified battery strings and places absorbed qualified battery strings on the photovoltaic module to complete the layout of the last row of battery strings, and then the module output unit2outputs the photovoltaic module whose layout is finished.

In S10, in a process of performing the S5 to the S9, an input of the next photovoltaic module and a position correction of the next photovoltaic module on the module input unit1are completed, that is, the next photovoltaic module is input onto the module input unit1and is in place, and a position of the next photovoltaic module on the module input unit1is corrected.

In S11, after the S9 is finished, input of the next photovoltaic module in place and position correction of the next photovoltaic module are completed, and the layout transfer unit4absorbs qualified battery strings and places absorbed qualified battery strings on the next photovoltaic module, to complete a layout of a first row of battery string on the next photovoltaic module and thus achieve the continuous layout operation.

In S12, in a process of performing the S9 and the S11, the tray transfer unit3descends to a position below the module output unit2and returns to the position below the module input unit1and is in place.

In the above-described three embodiments, when the layout transfer unit4typesets the first row of battery strings, the middle row of battery strings, and the last row of battery strings, positions of the layout transfer unit4for placing the battery strings may be the same or different. For example, when the first row of battery strings and the middle row of battery strings are typeset, positions of the layout transfer unit4for placing the first row of battery strings and the middle row of battery strings are the same, however, when the last row of battery strings are typeset, a position of the layout transfer unit4for placing the last row of battery strings is different from the positions of the layout transfer unit4for placing the first row of battery strings and the middle row of battery strings. Alternatively, when the middle row of battery strings and the last row of battery strings are typeset, positions of the layout transfer unit4for placing the battery strings are the same, however, when the first row of battery strings are typeset, a position of the layout transfer unit4for placing the first row of battery strings is different from the positions of the layout transfer unit4for placing the middle row of battery strings and the last row of battery strings. Alternatively, when the first row of battery strings, the middle row of battery strings and the last row of battery strings are typeset, positions of the layout transfer unit4for placing the battery strings are all the same. During the layout, the position change of the layout transfer unit4upon placing the battery strings is reduced as much as possible, so that on the one hand, the programming difficulty is reduced, and on the other hand, the layout precision is improved. Moreover, during the layout, the distance of the layout transfer unit4transferring in the second direction is reduced as much as possible, the time for absorbing the battery strings for transferring is shortened, and thus the layout efficiency is improved. In this method, placing positions of multiple rows of battery strings during layout are disposed at the same position, so that the time for absorbing the battery strings for transferring is shortened and thus the layout efficiency is improved.

In the method, the occupation of the tray transfer unit by the layout of the first row of battery strings is staggered with the occupation of the tray transfer unit by the layout of the last row of battery strings, that is, the layout of the first row of battery strings is designed to be performed on the module input unit1, or the last row of battery strings is designed to be performed on the module output unit2, so that the occupation of the tray transfer unit3is released. An operation that the tray transfer unit3moves from the module output unit2and returns to the position below the module input unit1in place is completed in this time period in which the occupation of the tray transfer unit3is released so that the operation does not occupy additional time for layout the battery strings. Moreover, in a time period in which after the photovoltaic module on the module input unit1is lifted and before the layout of the next photovoltaic module is performed, the operations of input the next photovoltaic module in place and position correction of the next photovoltaic module on the module input unit are completed without additionally occupy the layout time of the battery strings. Therefore, after a layout of a previous photovoltaic module is completed, the layout transfer unit4can continuously perform the layout of the next photovoltaic module without waiting for the next photovoltaic module midway, so that the tact time consumed in preparation of the layout of the next photovoltaic module is saved, the continuous layout process is achieved, and thus the layout efficiency is improved.

Compared with the related art, the high-speed layout method for the photovoltaic module and the high-speed layout device for the photovoltaic module provided in the present application have the following beneficial effects.

(1) The layout of the battery strings is divided into the layout of the first row of battery strings layout, the layout of the middle row of battery strings layout, and the layout of the last row of battery strings layout. The main layout transfer operation is undertaken by the tray transfer unit, the first row of battery strings are allocated to the module input unit or the last row of battery strings are allocated to the module output unit, so that the simultaneous occupation of the tray transfer unit is released, and a time period in which the tray transfer unit is released is used to complete the operation that the tray transfer unit moves from the module output unit and returns to the position below the module input unit in place without additionally occupying the layout time of the battery strings.

(2) In the time period in which after the photovoltaic module on the module input unit is lifted and before the layout of the next photovoltaic module is performed, the operations of input the next photovoltaic module in place and position correction of the next photovoltaic module on the module input unit are completed without additionally occupying the layout time of the battery strings. After the layout of the previous photovoltaic module is completed, the layout transfer unit can continuously perform the layout of the next photovoltaic module without waiting for the next photovoltaic module midway, so that the tact time consumed in preparation of the layout of the next photovoltaic module and in returning to the position below the module input unit by the tray transfer unit is saved, the continuous layout process is achieved, and thus the layout efficiency is improved.

(3) When layout battery strings by moving the glass, the layout of the middle row of battery strings is performed at the same position, the layout of the first row of battery strings and the layout of the last battery strings may be designed at the same position as the layout of the middle row of battery string or designed on a side of the layout of the middle row of battery string depending on the situation, so that the transfer distance of the layout transfer unit is reduced as a whole, and the consumption of the time for absorbing the battery strings for transferring is reduced, and thus the layout efficiency is improved.