Process Analysis And Structural Optimization Design Of Automatic Series Welding Machine

Recently,clean energy requirement is much more increasing and the requirement of PV modules is also in rapid growth in the Global world.At present,China is already the world’s largest manufacturer of photovoltaic products.At present,the price of PV modules is high and the service life of photovoltaic products needs to be improved.Therefore,manufacturers should not only to improve the quality of PV modules,but also to reduce the cost of the complicated process of PV modules.The subject of PV modules is solar cells and the core of PV modules is the series welding process.The problems of welding quality,welding efficiency and process cost caused by the existing domestic technology of manual welding,semi-automatic welding and automatic series welding machine of single line are becoming more and more prominent,and the demand for equipment is very large in China.The research of the thesis is aimed at domestic development of automatic series welding machine,refer to the research and development experience of high end automatic welding machine developed Germany and other developed countries in Europe,develops an economical,high efficient and reliable performance automatic series welding machine,is aiming at making it the forefront of international similar technology as soon as possible.First of all,research and develop a new type of automatic series welding machine in view of the current situation of the domestic manual welding,semi-automatic welding and the foreign automatic series welding machine of single line.Carry on the innovative design to its transmission structure,the movement principle,the craft principle and so on.The key innovative technologies include:The new infrared welding unit have been innovated in the in the innovative design of unit structure and technological concept,can improve the quality of welding and reduce the fragmentation rate of solar cell.The welding belt drying unit is carried on the innovation design in the unit structure,its structural design is small,reduces the unit cost,reduces the unit space,and is easy to maintain.The innovative design of silicon wafer fixed direction unit in the drive structure and movement principle meets the requirements of the production process,greatly reduces the cost of equipment and improves the stability of the positioning of solar cell.In addition to the innovative design of the three units,silicon wafer feeding unit,the silicon wafer manipulator unit,and silicon wafer transport unit are also improved.Its 3D model of the whole machine is built by the software Solid Works.The finite element analysis and modal analysis of the main parts is using by Ansys workbench finite element software,which can check the structural strength、stiffness and take the optimization design of the main parts of machine.Secondly,analyze the temperature field,stress field and Y direction displacement of solar cells in the process of the preheating、soft contact welding and infrared welding by Ansys workbench finite element software.The preheating process can effectively reduce the stress and deformation of the solar cell in the welding process.Welding effect of infrared welding way in reducing the thermal stress and residual stress is clearly superior to soft contact welding way.This is another innovation point in the development of this project.Finally,the Thermodynamic coupled field analysis of preheating and welding process have meaning to improve the welding quality,reduce the fragmentation rate and improve the service life of PV modules.Analysis shows that the fragmentation rate is estimated to decreased by 0.1%in theory and technology,the welding speed and production capacity of infrared preheating and welding process improve 35%and 30%compared the domestic similar technology,proves the correctness of theoretical analysis of the subject and the feasibility of optimization scheme,that the design results achieve the desired results.After the query of a large number of data references and inquiries at home and abroad,verify the design and development of the new type of automatic series welding machine.Compared with the domestic similar technology,it has reached the leading level.Compared with the international advanced level,it is greatly reducing the equipment cost.