CN111136407A - Automatic welding device and method - Google Patents
Automatic welding device and method Download PDFInfo
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- CN111136407A CN111136407A CN201811308351.3A CN201811308351A CN111136407A CN 111136407 A CN111136407 A CN 111136407A CN 201811308351 A CN201811308351 A CN 201811308351A CN 111136407 A CN111136407 A CN 111136407A
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- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 17
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
Abstract
The embodiment of the invention discloses an automatic welding device and a method, the device comprises a main control module, at least one welding head and at least one position detection module which corresponds to the at least one welding head one by one, the initial position of the welding head before welding and the welding position after welding are detected by the position detection module, and the initial position and the welding position are sent to the main control module, so that the main control module determines the welding result of the welding head according to the initial position and the welding position. According to the automatic welding device and the automatic welding method provided by the embodiment of the invention, the initial position before welding and the welding position after welding of the welding head are respectively detected by the position detection module, so that the main control module can determine the welding result of the welding head according to the initial position and the welding position, thereby timely obtaining the working condition in the welding process of the automatic welding device, preventing the yield of subsequent finished products from being reduced, and having higher stability and reliability.
Description
Technical Field
The embodiment of the invention relates to the technical field of automation, in particular to an automatic welding device and method.
Background
With the development of digitization and automation technologies and the high importance on the welding quality, automatic welding has developed into an advanced manufacturing technology, the automatic welding equipment plays an increasingly important role in various industrial applications, and the application range is rapidly expanding, for example, the automatic welding equipment can be applied to the manufacturing process of photovoltaic modules.
Because the single solar cell can not be directly used as a power supply, a plurality of single cells are required to be connected in series and in parallel and tightly packaged into a component, namely a photovoltaic component. The connecting device between the solar cell array of the photovoltaic module and the solar charging control device is a junction box of the photovoltaic module, and is mainly used for connecting and protecting the solar photovoltaic module, connecting electric power generated by the solar cell with an external circuit and conducting current generated by the photovoltaic module. And the junction box is usually connected with the interconnection bars of the solar cell matrix by welding. In the prior art, in order to save labor and improve the production efficiency of the photovoltaic module, the outgoing line of the interconnection strip of the solar cell matrix can be welded with the junction box through automatic welding equipment.
However, when the outgoing line and the junction box of the interconnection bar of the solar cell are welded by the existing automatic welding equipment, the phenomena of missing welding, false welding and the like exist, so that the use of the photovoltaic module and the yield of the photovoltaic module are influenced. Therefore, the welding result of the existing automatic welding equipment is poor in reliability and stability.
Disclosure of Invention
In view of this, embodiments of the present invention provide an automatic welding device and method, which can solve the technical problem of insufficient reliability and stability of an automatic welding device in the prior art, thereby causing the phenomena of insufficient solder joint and solder missing.
In a first aspect, an embodiment of the present invention provides an automatic welding device, including: the welding device comprises a main control module, at least one welding head and at least one position detection module which corresponds to the at least one welding head one to one;
the output end of the at least one position detection module is connected with the input end of the main control module and is used for detecting the initial position of the at least one welding head before welding and the welding position after welding and sending the initial position and the welding position to the main control module;
and the main control module is used for determining the welding result of the at least one welding head according to the initial position and the welding position.
In a second aspect, an embodiment of the present invention provides an automatic welding method, which is performed by using the above automatic welding apparatus, and includes:
the position detection module detects an initial position of a welding head before welding and a welding position after welding, and sends the initial position and the welding position to the main control module;
and the main control module determines the welding result of the welding head according to the initial position and the welding position.
The automatic welding device comprises a main control module, at least one welding head and at least one position detection module which corresponds to the at least one welding head one by one. The initial position of the welding head before welding and the welding position of the welding head after welding are detected through the position detection module, and the initial position and the welding position are sent to the main control module, so that the main control module determines the welding result of the welding head according to the initial position and the welding position. The technical problems that in the prior art, the reliability and the stability of an automatic welding device are insufficient, and therefore insufficient welding and missing welding phenomena occur are solved. Compared with the prior art, the initial position of the welding head before welding and the welding position of the welding head after welding are respectively detected through the position detection module, so that the main control module can determine the welding result of the welding head according to the initial position and the welding position, thereby timely obtaining the working condition in the welding process of the automatic welding device, preventing the yield from being reduced after subsequent finished products, and having higher stability and reliability.
Drawings
Fig. 1 is a schematic structural diagram of an automatic welding device according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a weld head according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a welded configuration of a weld head according to an embodiment of the present invention;
fig. 4 is a schematic structural diagram of an automatic welding device according to a second embodiment of the present invention;
FIG. 5 is a schematic perspective view of an automatic welding apparatus according to an embodiment of the present invention;
FIG. 6 is a schematic side view of an automatic welding device according to an embodiment of the present invention;
fig. 7 is a schematic structural diagram of an automatic welding device according to a third embodiment of the present invention;
FIG. 8 is a flow chart of an automatic welding method according to a fourth embodiment of the present invention;
fig. 9 is a flowchart of a method for determining a welding result of a welding head according to a fifth embodiment of the present invention;
FIG. 10 is a flow chart of an automatic welding method according to a sixth embodiment of the present invention;
fig. 11 is a flowchart of an automatic welding method according to a seventh embodiment of the present invention.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and examples. It is to be understood that the specific embodiments described herein are merely illustrative of the invention and are not limiting of the invention. It should be further noted that, for the convenience of description, only some of the structures related to the present invention are shown in the drawings, not all of the structures.
Example one
The automatic welding device provided by the embodiment of the invention is suitable for the automatic welding condition in industrial manufacturing, and can be applied to welding of a junction box and a solar cell matrix outgoing line in the manufacturing process of a photovoltaic module. Fig. 1 is a schematic view of an automatic welding apparatus according to an embodiment of the present invention. Referring to fig. 1, an automatic welding apparatus 100 according to an embodiment of the present invention includes a main control module 10, at least one welding head 20, and at least one position detection module 30 corresponding to the at least one welding head 20. Wherein, the output end of at least one position detection module 30 is connected with the input end of the main control module 10, and is used for detecting the initial position before welding and the welding position after welding of at least one welding head 20, and sending the initial position and the welding position to the main control module 10; the main control module 10 is configured to determine a welding result of at least one welding head 20 based on the initial position and the welding position.
It should be noted that at least one welding head 20 shown in fig. 1 includes a first welding head 21 and a second welding head 22, and the corresponding position detection module 30 includes a first position detection module 31 and a second position detection module 32. In other embodiments of the present invention, at least one of the welding heads 20 may include one or more welding heads, and the corresponding position detection module 30 may also include one or more welding heads, which are similar to the technical principle and implementation manner, but are not limited thereto.
Specifically, referring to fig. 1, the automatic welding apparatus 100 is capable of integrally connecting two or more kinds of materials of the same kind or different kinds by the welding head 20, while the position of the welding head 20 is changed as the welding process advances. In the actual welding process, the automatic welding device 100 may cause welding abnormalities, such as missing welding, insufficient welding, and the like, due to environmental conditions or self-working conditions, such as insufficient temperature and/or pressure of the welding head 20, or misalignment of the welding position of the welding head 20, and if the welding result after welding is not detected, the yield of subsequent finished products is reduced. Before the automatic welding device 100 performs welding, the position detection module 30 of the automatic welding device 100 detects the initial position of the corresponding welding head 20 and sends the initial position to the main control module 10. For example, the first position detection module 31 detects the initial position of the first welding head 21 and transmits the initial position of the first welding head 21 to the main control module 10; the second position detection module 32 detects the initial position of the second welding head and transmits the initial position of the second welding head 22 to the main control module 10. After the position detection module 20 detects the initial position of the welding head 20, the welding head 20 is activated to start welding. After the welding of the welding heads 20 of the automatic welding apparatus 100, the position detection module 30 again detects the welding positions of the corresponding welding heads 20 and transmits the welding positions to the main control module 10. The main control module 10 can determine the welding result of the welding head according to the initial position and the welding position of the welding head 20.
Illustratively, with reference to fig. 1, 2 and 3, for example, the lead-out wires 110 of the interconnection bar of the solar cell matrix (not shown) of the photovoltaic module are soldered to a junction box (not shown) by using the automatic soldering apparatus 100. The soldering position of the junction box of the photovoltaic module is provided with a tin stack 120, the tin stack 120 has a certain height, and the outgoing line 110 also has a certain height. Before the photovoltaic module is welded by the automatic welding device 100, the outgoing line 110 and the tin stack 120 are stacked together, the welding head 20 of the automatic welding device 100 is aligned to the welding position of the photovoltaic module, at this time, the welding head 20 has a certain height relative to the reference line M, the position is the initial position of the welding head 20, the height of the position is the height H1 of the initial position of the welding head 20, at this time, the position detection module 30 detects the height H1 of the initial position of the welding head 20 and sends the height H1 to the main control module 10; after the photovoltaic module is welded by the automatic welding device 100, the outgoing line 110 and the tin stack 120 are connected into a whole, and the welding head heats and/or pressurizes the outgoing line 110 and the tin stack 120 in the welding process, so that the heights of the outgoing line 110 and the tin stack 120 are changed to a certain extent, the position of the welding head 20 for correspondingly welding the outgoing line 110 and the tin stack is changed accordingly, the position is the welding position of the welding head 20, the height of the position is the height H2 of the welding position of the welding head 20, and the position detection module 30 detects the height H2 of the welding position of the welding head 20 and sends the height H2 to the main control module 10.
Since the height H1 of the initial position and the height H2 of the bonding position have a bonding height difference, the bonding height difference between the height H1 of the initial position and the height H2 of the bonding position of the bonding tool 20 is small or no bonding height difference occurs during bonding due to misalignment of the bonding position of the bonding tool 20 or abnormality of the heating temperature and/or the pressure of the automatic bonding apparatus 100. When the automatic soldering apparatus 100 integrally connects the lead-out wire 110 and the tin stack 120 through the soldering tip 20, the height H1 of the initial position of the soldering tip 20 and the height H2 of the soldering position have a corresponding soldering height difference, which may be, for example, a preset height difference. Thus, the main control module 10 determines the welding result of the welding head 20 by calculating whether the welding height difference between the height H1 of the initial position of the welding head 20 and the height H2 of the welding position reaches a preset height difference. That is, when the welding height difference does not reach the preset height difference, the welding result of the welding head 20 is abnormal; or, when the welding height difference reaches the preset height difference, the welding result of the welding head 20 is qualified.
It should be noted that, for the automatic welding apparatus 100 having two or more welding heads, each welding head can be controlled separately for welding, or several welding heads can be controlled simultaneously for welding, and the position detection module corresponding to the welding head can detect the initial position and the welding position of the corresponding welding head without being affected by other welding heads and/or position detection modules. For example, in the present embodiment, the first welding head 21 and the second welding head 22 perform welding work independently, or may perform welding work simultaneously, and the first position detection module 31 detects the initial position and the welding position of the first welding head 21 without being affected by the second welding head 22 and the second position detection module 32. The welding operation of the automatic welding device 100 may meet practical requirements, and is not limited herein.
In the embodiment, the initial position of the welding head before welding and the welding position of the welding head after welding are respectively detected by the position detection module, so that the main control module can determine the welding result of the welding head according to the initial position and the welding position, thereby timely obtaining the working condition in the welding process of the automatic welding device, preventing the yield from being reduced after subsequent finished products, and having higher stability and reliability.
Example two
The embodiment is optimized on the basis of the embodiment, and provides a welding head control module which is preferably added on the basis of the embodiment. Fig. 4 is a schematic structural diagram of an automatic welding device according to a second embodiment of the present invention. As shown in fig. 4, an automatic welding apparatus according to an embodiment of the present invention includes: the welding system comprises a main control module 10, at least one welding head 20, at least one position detection module 30 and a welding head control module 40, wherein the position detection module 30 corresponds to the welding head one by one. The input end of the welding head control module 40 is connected with the output end of the main control module 10, the output end of the welding head control module 40 is connected with the control end of at least one welding head 20, and the welding head control module is used for acquiring a welding control signal of the main control module 10 when the welding height difference between the height of the initial position and the height of the welding position is smaller than a preset height difference, and controlling at least one welding head 20 to perform supplementary welding on a welded device according to the welding control signal.
Specifically, the position detection module 30 sends the detected initial position of the welding head 20 before welding and the detected welding position after welding to the main control module 10, and the main control module 10 can determine the welding result of the welding head 20 according to the initial position and the welding position, where the welding result includes a result of welding abnormality and a result of welding qualification. The qualified welding result can be that the height difference between the height of the initial position and the height of the welding position reaches a preset height difference; the result of the welding abnormality may be that a height difference between the height of the initial position and the height of the welding position does not reach a preset height difference, that is, the welding height difference is smaller than the preset height difference.
When the welding height difference is smaller than the preset height difference, the welded devices welded by the welding head 20 in the automatic welding device 100 may have the phenomena of cold joint, missing joint and the like. At this time, when detecting that the welding height difference is smaller than the preset height difference, the main control module 10 sends a welding control signal to the welding head control module 40, so that the welding head control module 40 controls the welding head 20 to perform supplementary welding on the welded device.
After the welding head 20 performs supplementary welding on the welded device, the welding position of the supplementary welding of the welding head 20 can be detected again through the position detection module, and the welding position of the supplementary welding is sent to the main control module 10, so that the main control module 10 determines the welding result of the welding head 20 after the supplementary welding. If the main control module 10 determines the welding result of the welding head 20 as abnormal again, supplementary welding can be selected again until the welding result is qualified. In the actual welding process, since the device to be welded needs to be heated and/or pressurized during welding, the material of the device to be welded may deteriorate after being pressurized and/or heated for multiple times, and the welding head 20 may shift along with the increase of the welding times and the change of the welding conditions, which may cause the position detected by the position detection module 30 to be inaccurate. Meanwhile, in the manufacturing process, the repeated supplementary welding consumes time, and the welded devices are accumulated in the manufacturing process, so that the conditions of flow line congestion and the like are generated, and the work of the automatic welding device 100 is not utilized.
In order to improve the welding efficiency of the automatic welding device and reduce the welding cost, the main control module in the automatic welding device 100 according to the embodiment of the present invention only sends a welding control signal to the welding head control module 40 once when detecting that the welding height difference is smaller than the preset height difference, so that the welding head control module 40 controls the welding head 20 to perform only one supplementary welding on the welded device. If the welding result of the welding head 20 is determined to be abnormal again according to the received welding position of the primary supplementary welding after the primary supplementary welding, the main control module 10 directly determines the welded device as a waste part and pushes the waste part out of the production line.
In addition, after the position detection module 30 detects the initial position of the corresponding welding head 20, the welding head control module 40 may also control the corresponding welding head 20 to start welding.
Optionally, as shown in fig. 4, 5 and 6, the bonding tool control module includes: a horn controller 42 and a horn slide guide 41. The welding head 20 is connected with the welding head sliding guide rod 41 in a sliding mode, the input end of the welding head controller 42 is connected with the output end of the main control module 10, and the output end of the welding head controller 42 is connected with the control end of the welding head 20; the welding head controller 42 is used for controlling the welding head 20 to slide on the welding head sliding guide rod according to the welding control signal sent by the main control module 10, so that the welding head 20 welds the welded device.
Specifically, when the welding head 20 of the automatic welding device 100 welds the welded component, the main control module 10 determines that the welding result of the welding head 20 is abnormal, that is, the welding height difference between the height of the initial position and the height of the welding position is smaller than the preset height difference, at this time, the welding head controller 42 of the welding head control module 40 receives the welding control signal sent by the main control module 10, and controls the corresponding welding head 20 to slide on the welding head sliding guide rod 41 corresponding to the welding control signal, and the sliding direction may be, for example, perpendicular to the welded component, so as to perform supplementary welding on the welded component.
In addition, after the position detection module 30 detects the initial position of the welding head 20, the welding head controller 42 of the welding head control module 40 may control the welding head 40 to start welding. At this time, the welding head 40 is also slid on the welding head slide guide 41 to weld the device to be welded.
It should be noted that, for an automatic welding apparatus 100 having a plurality of welding heads, the welding head controller 42 of the welding head control module 40 may be selected to be one or a plurality corresponding to the plurality of welding heads. When one welding head controller 42 is provided, the corresponding welding head can be controlled to start through the corresponding control signal; when the weld head controller 42 is a plurality of weld heads corresponding to a plurality of weld heads, the weld head controller 42 may control the activation of the corresponding weld heads, respectively. The number of the welding head sliding guide rods is matched with that of the welding heads, so that the sliding of each welding head is not interfered with each other.
Optionally, with continued reference to fig. 4, the automated welding apparatus 100 further includes at least one position adjustment module 50 in one-to-one correspondence with at least one of the welding heads 20. Wherein the position adjustment module is configured to adjust the welding head 20 to the initial position.
Specifically, before the welding is started, if the position of the welding head 20 of the automatic welding device 100 is misaligned with the position of the device to be welded, the welding position of the welding head 20 is inaccurate, which may result in abnormal welding results, and the position detection module 30 may not detect the initial position of the welding head 20. Therefore, before the welding head 20 initiates welding, the welding head 20 is adjusted to the initial position of the welding head 20, i.e., the welding head 20 is aligned by the weld points of the welding device. The adjustment of the position adjustment module 50 to the weld head 20 may be manually adjusted or automatically controlled.
It should be noted that the position adjusting module 50 corresponds to one welding head 20, and is determined according to the number of welding heads 20, which is not limited herein. Fig. 7 is a diagram illustrating the embodiment, that is, the first position adjustment module 51 corresponds to the first welding head 21 and can adjust the first welding head 21 to the initial position of the first welding head 21; the second position adjustment module 52 corresponds to the second welding head 22 and may adjust the second welding head 22 to an initial position of the second welding head 22.
Alternatively, referring to fig. 4, 5 and 6 in combination, the adjustment of the position adjustment module 50 to the weld head 20 may be manually adjusted. The position adjustment module 50 may include a mechanical micrometer 501, a first support plate 53, a second support plate 53, and a compression spring 502. The compression spring 502 is fixed between the first support plate 53 and the second support plate 54, and the mechanical micrometer 501 is located on one side of the first support plate 53 away from the compression spring 502; one end of the horn slide guide 41 is fixed to the side of the second support plate 54 away from the compression spring 502, and the other end of the horn slide guide 41 is slidably connected to the horn 20.
For example, when two welding heads 20, i.e., a first welding head 21 and a second welding head 22, are included in the automatic welding apparatus 100, the first position adjustment module 51 corresponding to the first welding head 21 may include a first mechanical micrometer 511 and a first compression spring 512, the second position adjustment module 52 corresponding to the second welding head 22 may include a second mechanical micrometer (not shown) and a second compression spring (not shown), and the first support plate 53 and the second support plate 54 may be support plates common to the respective members of the first position adjustment module 51 and the second position adjustment module 52.
Here, the first position detection module 51 is described as an example of adjusting the position of the first welding head 21. The first mechanical micrometer 511 of the first position detection module 51 is divided into an upper adjustment mechanical micrometer and a lower adjustment mechanical micrometer, the first welding head 21 can be adjusted to move upwards along the corresponding welding head sliding guide rod 41 through the upper adjustment mechanical micrometer, that is, the height of the first welding head 21 is increased, and the upwards adjusted height value of the first welding head 21 can be determined by reading the scale of the upper adjustment mechanical micrometer; the downward movement of the first welding head 21 along the corresponding welding head sliding guide rod 41 can be adjusted by the lower adjusting machine, namely, the height of the first welding head 21 is reduced, and the downward adjusting height value of the first welding head 21 can be determined by reading the scale of the lower adjusting machine micrometer. And the compression spring 512 between the first support plate 53 and the second support plate 54 has a certain tension, and can fix and support the components above the first support plate 53 and the components below the second support plate 54, such as the first mechanical micrometer 511, the horn slide guide 41, and the first horn 21, to maintain the components at the adjusted positions. Meanwhile, the compression spring 502 can also play a certain role in cushioning, thereby protecting the welding head 20 and the welded device.
Alternatively, referring to fig. 4 and 5 in combination, the position detection module 30 includes a micrometer 301 and a micrometer probe (not shown). The micrometer probe rod is positioned at the signal acquisition end of the micrometer 301, and the output end of the micrometer 301 is connected with the input end of the main control module 10; the micrometer 301 is used for detecting the initial position and the welding position of the welding head 20 through the micrometer probe rod and transmitting the initial position and the welding position to the main control module 10.
Illustratively, with continued reference to fig. 4, 5, and 6, when two welding heads 20, i.e., a first welding head 21 and a second welding head 22, are included in the automatic welding apparatus 100, the first position detection module 31 corresponding to the first welding head 21 includes a first micrometer 311 and a first micrometer probe 312, and the second position detection module 32 corresponding to the second welding head 22 includes a second micrometer (not shown) and a second micrometer probe (not shown). The micrometer probe rod can be extended and retracted according to the position change of the welding head 20, and a position detection sensor, which may be an optical fiber, for example, is disposed on the micrometer probe rod, so that the height of the welding head 20 can be detected. The micrometer feeler lever transmits the detected position of the welding head 20 to the micrometer, generates a corresponding initial position and welding position and transmits the initial position and welding position to the main control module 10 for analysis processing.
In addition, the automatic control device 100 further includes a supporting component, a fixing component, a protecting component, etc., the functions and positions of which can be predicted by those skilled in the art and will not be described in detail herein.
In the embodiment, by adding the welding head control module, when the welding height difference between the height of the initial position and the height of the welding position is smaller than the preset height difference, the main control module can control the welding head to perform supplementary welding on the welded device through the welding head control module, so that the yield of finished products is further improved, and the reliability and the stability of the automatic welding device are further improved.
EXAMPLE III
The present embodiment is optimized based on the above embodiments, and provides a preference, and a positioning detection module is added based on the above embodiments. Fig. 7 is a schematic structural diagram of an automatic welding device according to a third embodiment of the present invention. As shown in fig. 7, the automatic welding apparatus 100 provided in this embodiment further includes, in addition to the above embodiments: the detection module 60 is located. The output end of the positioning detection module 60 is connected with the input end of the main control module 10, and is used for performing positioning detection on the position of the welding head 20 before welding, or performing positioning detection on the position of the welding head 20 after welding, and sending the positioning detection result to the main controller 10; the main control module 10 is further configured to send a positioning control signal to the welding head control module 40 when the position of the welding head 20 deviates from the initial position, so that the welding head control module 40 controls the welding head 20 to move to the initial position; or the main control module 10 is further configured to determine the welding result of the welding head 20 according to the position of the welding head 20 after welding.
Specifically, the positioning detection module 60 can detect the position of the welding head 20 before welding and the position of the welding head after welding, and can directly feed back the detection result to the main control module 10. The positioning detection module 60 optionally includes a Charge Coupled Device (CCD), collects image information of the welding head and the welded device through the CCD, generates the image information into a signal that can be processed by the main control module 10, and sends the signal to the main control module 10, so that the main control module 10 sends out a corresponding control signal according to the signal generated by the image information.
For example, before the welding head 20 starts welding, the CCD of the positioning detection module 60 can perform image acquisition on the welding head 20, and generate the acquired image as information analytically calculated by the main control module 10, so that the main control module 10 can determine whether the welding head 20 is located at its initial position according to the information. When the horn deviates from its initial position, the main control module 10 sends a positioning control signal to the horn control module 40 so that the horn control module 40 controls the horn 20 to move to its initial position. Correspondingly, after the welding head 20 is welded, the CCD of the positioning detection module 60 may also be used to perform image acquisition on the welding head, and generate corresponding information that the main control module 10 can analyze and calculate, so that the main control module 10 determines the welding result of the welding head 20. When the welding result is abnormal, determining that the welded device is a waste part; and when the welding result is qualified, determining that the welding device is a qualified product.
Optionally, with continued reference to fig. 7, in order to enable the main control module 10 of the automatic welding device 100 to calculate the height difference between the analyzed height of the initial position of the welding head and the height of the welding position, and to enable visual display of the initial position and the welding position, a display module 70 is further included in the automatic welding device 100. The input end of the display module 70 is connected to the output end of the main control module 10, and is configured to receive and display the welding result, the initial position, and the welding position sent by the main control module 10. Accordingly, when the welding result of the welding head 20 is abnormal, the display module 10 may also directly display the reason for the abnormality to prompt the abnormal welding result.
Optionally, with continued reference to fig. 7, the automated welding apparatus 100 further includes an alarm module 80. The input end of the alarm module 80 is connected to the output end of the main control module 10, and is configured to receive an alarm control signal sent by the main control module when a welding height difference between the height of the initial position of the welding head 20 and the height of the welding position is smaller than a preset height difference, and to alarm according to the alarm control signal. With this arrangement, the maintenance worker can know the welding abnormality of the automatic welding device 100 in time. Meanwhile, the alarm module 80 may also alarm the automatic welding device 100 of abnormal operation, so that the maintenance personnel can know and maintain the operation in time.
In the embodiment, the positioning detection module is added to detect the position of the welding head before welding and the position of the welding head after welding, so that the main control module of the automatic welding device can accurately judge the welding result of the welding head, and the stability and the reliability of the automatic welding device are further improved.
Example four
The automatic welding method provided by the embodiment of the invention is suitable for the automatic welding condition in industrial manufacturing, and can be applied to welding of a junction box and a solar cell matrix outgoing line in the manufacturing process of a photovoltaic module. The automatic welding method is executed by adopting the automatic welding device provided by the embodiment of the invention. Fig. 8 is a flowchart of an automatic welding method according to a fourth embodiment of the present invention. In the embodiment, the automatic welding apparatus is as shown in fig. 1, and the automatic welding apparatus at least includes a main control module 10, at least one welding head 20, and at least one position detection module 30 corresponding to the at least one welding head one to one. With reference to fig. 1 and 8, the automatic welding method provided in this embodiment includes:
s410, the position detecting module 30 detects an initial position of the welding head 20 before welding and a welding position after welding, and sends the initial position and the welding position to the main control module 10.
Specifically, the position detection module 30 detects an initial position before welding and a welding position after welding of the welding head 20, and sends the initial position and the welding position to the control module 10. Before the welding head 20 starts welding, the welding head 20 is aligned to a welded device, the position of the welding head 20 at this time is the initial position of the welding head 20, and the position detection module 30 detects the position of the welding head 20 at this time and sends the position to the main control module 10; after the welding of the welding head 20 is completed, the welded devices are connected together, and the position of the welding head 20 is changed accordingly, at this time, the position of the welding head 20 is the welding position of the welding head 20, and the position detection module 30 detects the position of the welding head 20 at this time and sends the position to the main control module 10.
For example, the soldered device can be a junction box of a photovoltaic module and a lead-out wire of a solar cell matrix. The junction box is provided with a tin stack for welding, the outgoing line can be fixed on the welding head 20 before the welding head 20 starts welding, the outgoing line and the tin stack are aligned and stacked together through the welding head 20, meanwhile, the welding head 20 is located on the stacking layer of the outgoing line and the tin stack, the position of the welding head 20 is the initial position of the welding head 20 at the moment, and the position detection module 30 detects the initial position of the welding head 20 and sends the initial position to the main control module 10. When the bond head 20, lead wires, and tin stack are aligned, the bond head 20 initiates bonding. In the soldering process, the lead-out wire and the tin stack are deformed under the influence of pressure and/or temperature, and the deformation is mainly characterized in that the stacking height of the lead-out wire and the tin stack is gradually reduced. Also, the position of the bonding tip 20 may vary during the bonding process as the tin stack and lead lines vary. After the welding is finished, the stacking height of the tin stack and the outgoing line is reduced, the position of the welding head 20 is changed accordingly, the position of the welding head 20 is the welding position of the welding head 20 at the moment, and the position detection module 30 detects the welding position of the welding head 20 and sends the welding position to the main control module 10.
And S420, determining the welding result of the welding head 20 by the main control module 10 according to the initial position and the welding position.
Specifically, the main control module 10 receives the initial position of the welding head 20 sent by the position detection module 30 before welding, and the welding position of the welding head 20 after welding. The main control module 10 may analyze the welding result of the welding head 20 by comparing the initial position and the welding position of the welding head 20, and determine the current welding result of the welding head 20 according to the analyzed welding result, where the welding result may be, for example, a welding pass and a welding abnormality of the welding head 20 to the device to be welded, and the welding abnormality may include a cold joint, a missing joint, and the like. As in the above example, the main control module 10 can determine whether the junction box and the outgoing line of the solar cell square matrix are connected together through the initial position and the welding position of the welding head 20, that is, when the junction box and the outgoing line are connected together, it is determined that the welding result of the welding head 20 is qualified; when the terminal box and the lead-out wire are connected falsely or not, the welding result of the welding head 20 is determined to be abnormal.
In the embodiment, the initial position of the welding head before welding and the welding position of the welding head after welding are respectively detected by the position detection module, so that the main control module can determine the welding result of the welding head according to the initial position and the welding position, thereby timely obtaining the working condition in the welding process of the automatic welding device, preventing the yield from being reduced after subsequent finished products, and having higher stability and reliability.
EXAMPLE five
The present embodiment is optimized on the basis of the above embodiment, and it is preferable to embody that the main control module determines the welding result of the welding head according to the initial position and the welding position of the welding head on the basis of the above embodiment, specifically that: calculating a weld height difference between the height of the initial position and the height of the weld location; when the welding height difference reaches the preset height difference, determining that the welding detection result is qualified; or when the welding height difference is smaller than the preset height difference, determining that the welding detection result is abnormal. Fig. 9 is a flowchart of a method for determining a welding result of a welding head according to a fifth embodiment of the present invention. Referring to fig. 1, 2, 3 and 9, the method for determining the welding result of the welding head 20 according to the present embodiment includes:
s621, calculating a welding height difference between the height H1 of the initial position and the height H2 of the welding position;
s622, judging whether the welding height difference reaches a preset height difference; if yes, go to S623; if not, go to S624.
S623, determining that the welding result is qualified;
and S624, determining that the welding result is abnormal.
Specifically, since the height H1 of the initial position of the bonding tool 20 and the height H2 of the bonding position have a bonding height difference, the bonding height difference between the height H1 of the initial position of the bonding tool 20 and the height H2 of the bonding position is small or no bonding height difference occurs during bonding due to misalignment of the bonding position of the bonding tool 20 or abnormality of the heating temperature and/or the pressure of the automatic bonding apparatus 100. When the automatic soldering apparatus 100 integrally connects the lead-out wire 110 and the tin stack 120 through the soldering tip 20, the height H1 of the initial position of the soldering tip 20 and the height H2 of the soldering position have a corresponding soldering height difference, which may be, for example, a preset height difference. Thus, the main control module 10 determines the welding result of the welding head 20 by calculating whether the welding height difference between the height H1 of the initial position of the welding head 20 and the height H2 of the welding position reaches a preset height difference. That is, when the welding height difference does not reach the preset height difference, the welding result of the welding head 20 is abnormal; or, when the welding height difference reaches the preset height difference, the welding result of the welding head 20 is qualified.
In the embodiment, the height difference between the height of the initial position of the welding head and the height of the welding position is calculated through the main control module, and the welding result of the welding head is determined, so that the working condition of the automatic welding device in the welding process can be obtained in time, the reduction of the yield after subsequent finished products is prevented, and the welding device has higher stability and reliability.
EXAMPLE six
The present embodiment is optimized on the basis of the above embodiments, and provides a method for controlling the welding head to perform supplementary welding after determining the welding result of the welding head, which is preferable on the basis of the above embodiments. Referring to fig. 4, the automatic welding apparatus 100 of the present embodiment further includes a welding head control module 40 based on the above-mentioned embodiment, an input end of the welding head control module 40 is connected to an output end of the main control module 10, and an output end of the welding head control module 40 is connected to a control end of at least one welding head 20. Fig. 10 is a flowchart of an automatic welding method according to a sixth embodiment of the present invention. With reference to fig. 4 and 6, the automatic welding method of the present embodiment includes:
s610, a position detection module detects an initial position of a welding head before welding and a welding position after welding, and sends the initial position and the welding position to a main control module;
s620, the main control module determines a welding result of the welding head according to the initial position and the welding position;
and S630, when the welding height difference is smaller than the preset height difference, the welding head control module acquires a welding control signal sent by the main control module, and controls the welding head to perform supplementary welding on the welded device according to the welding control signal.
Specifically, when the welding height difference is smaller than the preset height difference, the welded devices welded by the welding head 20 in the automatic welding device 100 may have the phenomena of cold joint, missing joint, and the like. At this time, when detecting that the welding height difference is smaller than the preset height difference, the main control module 10 sends a welding control signal to the welding head control module 40, so that the welding head control module 40 controls the welding head 20 to perform supplementary welding on the welded device.
After the welding head 20 performs supplementary welding on the welded device, the welding position of the supplementary welding of the welding head 20 can be detected again through the position detection module, and the welding position of the supplementary welding is sent to the main control module 10, so that the main control module 10 determines the welding result of the welding head 20 after the supplementary welding. If the main control module 10 determines the welding result of the welding head 20 as abnormal again, supplementary welding can be selected again until the welding result is qualified. In the actual welding process, since the device to be welded needs to be heated and/or pressurized during welding, the material of the device to be welded may deteriorate after being pressurized and/or heated for multiple times, and the welding head 20 may shift along with the increase of the welding times and the change of the welding conditions, which may cause the position detected by the position detection module 30 to be inaccurate. Meanwhile, in the manufacturing process, the repeated supplementary welding consumes time, and the welded devices are accumulated in the manufacturing process, so that the conditions of flow line congestion and the like are generated, and the work of the automatic welding device 100 is not utilized.
In order to improve the welding efficiency of the automatic welding device and reduce the welding cost, the main control module in the automatic welding device 100 according to the embodiment of the present invention only sends a welding control signal to the welding head control module 40 once when detecting that the welding height difference is smaller than the preset height difference, so that the welding head control module 40 controls the welding head 20 to perform only one supplementary welding on the welded device. If the welding result of the welding head 20 is determined to be abnormal again according to the received welding position of the primary supplementary welding after the primary supplementary welding, the main control module 10 directly determines the welded device as a waste part and pushes the waste part out of the production line.
Optionally, with continuing reference to fig. 4, the automatic welding device 100 further includes, based on the above-described embodiment: at least one position adjustment module 50 in one-to-one correspondence with at least one of the weld heads 20. On the basis of the above embodiment, before the position detection module 30 detects the initial position of the welding head 20 before welding and the welding position after welding, the automatic welding method further includes: the position adjustment module adjusts the welding head to the initial position.
Specifically, before starting welding, if the position of the welding head 20 is misaligned with the position of the device to be welded, the welding position of the welding head 20 is inaccurate, which results in abnormal welding results, and the position detection module 30 cannot detect the initial position of the welding head 20. Therefore, before the welding head 20 initiates welding, the welding head 20 is adjusted to the initial position of the welding head 20, i.e., the welding head 20 is aligned by the weld points of the welding device. The adjustment of the position adjustment module 50 to the weld head 20 may be manually adjusted or automatically controlled.
In the embodiment, when the welding height difference between the height of the initial position and the height of the welding position is smaller than the preset height difference, the main control module can control the welding head to perform supplementary welding on the welded device through the welding head control module, so that the yield of finished products is further improved, and the reliability and the stability of the automatic welding device are further improved.
EXAMPLE seven
The present embodiment is optimized based on the above embodiments, and provides a preferable mode, and positioning detection of the initial position of the welding head before welding and the welding position of the welding head after welding are respectively added on the basis of the above embodiments. As shown in fig. 7, on the basis of the above embodiment, the automatic welding device 100 of the present embodiment further includes a positioning detection module 60, and an output end of the positioning detection module 60 is connected to an input end of the main control module 10. Fig. 11 is a flowchart of an automatic welding method according to a seventh embodiment of the present invention. With reference to fig. 11 and the combination 7, the automatic welding method of the present embodiment includes:
s710, the positioning detection module performs positioning detection on the position of the welding head before welding and sends a positioning detection result to the main control module;
s720, when the position of the welding head deviates from the initial position, the main control module sends a positioning control signal to the welding head control module, so that the welding head control module controls the welding head to move to the initial position.
Specifically, the positioning detection module 60 detects the position of the welding head 20 before welding is started, and the detection method may be, for example, sensing the position information of the welding head 20 by a sensor or acquiring the image information of the welding head 20 by an image information acquisition device, generating the position information sensed by the sensor or the image information acquired by the image acquisition device as a positioning detection result, and sending the positioning detection result to the main control module 10, so that the main control module 10 performs analysis and processing. If the main control module 10 analyzes that the position of the welding head 20 is deviated from the initial position of welding before welding is started, that is, the position of the welding head 20 aligned with the device to be welded, the main control module 10 may send a positioning control signal to the welding head control module 40, so that the welding head control module 40 will control the welding head 20 to move to the initial position. If the main control module 10 analyzes that the position of the welding head 20 is the initial position before starting, the welding head 20 can be directly controlled to start welding.
S730, detecting an initial position of a welding head before welding and a welding position of the welding head after welding by a position detection module, and sending the initial position and the welding position to a main control module;
s740, the main control module determines a welding result of the welding head according to the initial position and the welding position;
s750, the positioning detection module performs positioning detection on the position of the welding head after welding and sends a positioning detection result to the main control module;
and S760, the main control module determines the welding result of the welding head according to the position of the welding head after welding.
Specifically, the master control module 10 is capable of determining a welding result of the welding head 20 based on the initial position and the welding position of the welding head 20, the welding result being empirically calculated. To further verify the welding results of the weld head 20, the position of the weld head 20 may also be detected by the position detection module 60 after welding. Similarly, the position of the welding head 20 detected by the positioning detection module 60 may be selected by sensing the position information of the welding head 20 by using a sensor or collecting the image information of the welding head 20 by using an image information collecting device, and sending the position information sensed by the sensor and the image information collected by the image collecting device to the main control module 10 after generating a positioning detection result, so that the main control module 10 performs analysis and processing. If the main control module 10 determines that the welding result of the welding head 20 is abnormal according to the positioning detection result of the positioning detection module after welding, the welding can be returned to supplement welding again or directly treated as waste; if the main control module 10 determines that the welding result of the welding head 20 is qualified according to the positioning detection result of the positioning detection module after welding, the process is transferred to the next process.
Optionally, with continued reference to fig. 7, the automatic welding device 100 further includes a display module 70 on the basis of the above-described embodiment, and an input end of the display module 70 is connected to an output end of the main control module 10. On the basis of the above embodiment, after the main control module determines the welding result of the welding head according to the initial position and the welding position, the automatic welding method further includes: and the display module receives and displays the welding result, the initial position and the welding position sent by the main control module.
Optionally, with continued reference to fig. 7, the automatic welding apparatus 100 further comprises an alarm module 80 on the basis of the above-described embodiment, an input of the alarm module 80 being connected to an output of the main control module 10. On the basis of the above embodiment, after the main control module determines the welding result of the welding head according to the initial position and the welding position, the automatic welding method further includes: and when the welding height difference between the height of the initial position and the height of the welding position is smaller than the preset height difference, the alarm module receives an alarm control signal sent by the main control module and gives an alarm according to the alarm control signal.
In the embodiment, the position of the welding head before welding and the position of the welding head after welding are detected, so that the main control module of the automatic welding device can accurately judge the welding result of the welding head, and the stability and the reliability of the automatic welding device are further improved.
The automatic welding method according to the embodiment of the present invention is performed by using the automatic welding device according to the above embodiments, and the technical principle and the technical effect thereof are similar, and are not described herein again.
It is to be noted that the foregoing is only illustrative of the preferred embodiments of the present invention and the technical principles employed. It will be understood by those skilled in the art that the present invention is not limited to the particular embodiments described herein, but is capable of various obvious changes, rearrangements and substitutions as will now become apparent to those skilled in the art without departing from the scope of the invention. Therefore, although the present invention has been described in greater detail by the above embodiments, the present invention is not limited to the above embodiments, and may include other equivalent embodiments without departing from the spirit of the present invention, and the scope of the present invention is determined by the scope of the appended claims.
Claims (17)
1. An automatic welding device, comprising: the welding device comprises a main control module, at least one welding head and at least one position detection module which corresponds to the at least one welding head one to one;
the output end of the at least one position detection module is connected with the input end of the main control module and is used for detecting the initial position of the at least one welding head before welding and the welding position after welding and sending the initial position and the welding position to the main control module;
and the main control module is used for determining the welding result of the at least one welding head according to the initial position and the welding position.
2. The apparatus of claim 1, further comprising: a welding head control module;
the input end of the welding head control module is connected with the output end of the main control module, the output end of the welding head control module is connected with the control end of the at least one welding head, and the welding head control module is used for acquiring a welding control signal of the main control module when the welding height difference between the height of the initial position and the height of the welding position is smaller than a preset height difference, and controlling the at least one welding head to perform supplementary welding on a welded device according to the welding control signal.
3. The apparatus of claim 2, wherein the horn control module comprises: a welding head controller and a welding head sliding guide rod;
the welding head is connected with the welding head sliding guide rod in a sliding mode, the input end of the welding head controller is connected with the output end of the main control module, and the output end of the welding head controller is connected with the control end of the welding head;
the welding head controller is used for controlling the welding head to slide on the welding head sliding guide rod according to the welding control signal so as to enable the welding head to weld the welded device.
4. The apparatus of claim 3, further comprising: at least one position adjusting module in one-to-one correspondence with the at least one welding head;
the position adjusting module is used for adjusting the welding head to the initial position.
5. The apparatus of claim 4, wherein the position adjustment module comprises a mechanical micrometer, a first support plate, a second support plate, and a compression spring;
the compression spring is fixed between the first support plate and the second support plate, and the mechanical micrometer is positioned on one side of the first support plate, which is far away from the compression spring;
one end of the welding head sliding guide rod is fixed on one side, away from the compression spring, of the second supporting plate, and the other end of the welding head sliding guide rod is connected with the welding head in a sliding mode.
6. The apparatus of claim 1, wherein the position detection module comprises a micrometer and a micrometer probe;
the micrometer probe rod is positioned at the signal acquisition end of the micrometer, and the output end of the micrometer is connected with the input end of the main control module;
the micrometer is used for detecting the initial position and the welding position through the micrometer feeler lever and sending the initial position and the welding position to the main control module.
7. The apparatus of claim 2, further comprising: a positioning detection module;
the output end of the positioning detection module is connected with the input end of the main control module and is used for performing positioning detection on the position of the welding head before welding or the position of the welding head after welding and sending the positioning detection result to the main controller;
the main control module is further used for sending a positioning control signal to the welding head control module when the position of the welding head deviates from the initial position, so that the welding head control module controls the welding head to move to the initial position; or the main control module is also used for determining the welding result of the welding head according to the position of the welding head after welding.
8. The apparatus of claim 1, further comprising: a display module;
the input end of the display module is connected with the output end of the main control module and used for receiving and displaying the welding result, the initial position and the welding position sent by the main control module.
9. The apparatus of claim 1, further comprising: an alarm module;
the input end of the alarm module is connected with the output end of the main control module and used for receiving an alarm control signal sent by the main control module when the welding height difference between the height of the initial position and the height of the welding position is smaller than the preset height difference and giving an alarm according to the alarm control signal.
10. An automatic welding method, characterized by being performed by the automatic welding apparatus according to any one of claims 1 to 9, the method comprising:
the position detection module detects an initial position of a welding head before welding and a welding position after welding, and sends the initial position and the welding position to the main control module;
and the main control module determines the welding result of the welding head according to the initial position and the welding position.
11. The method of claim 10, wherein the master control module determines a weld result for the weld head based on the initial position and the weld position, comprising:
calculating a weld height difference between the height of the initial position and the height of the weld location;
when the welding height difference reaches the preset height difference, determining that the welding result is qualified; alternatively, the first and second electrodes may be,
and when the welding height difference is smaller than the preset height difference, determining that the welding result is abnormal.
12. The method of claim 11, wherein the automated welding device further comprises: a welding head control module; the input end of the welding head control module is connected with the output end of the main control module, and the output end of the welding head control module is connected with the control end of the at least one welding head; when the welding height difference is smaller than the preset height difference, the method further comprises the following steps:
and the welding head control module acquires a welding control signal sent by the main control module when the welding height difference is smaller than the preset height difference, and controls the welding head to perform supplementary welding on the welded device according to the welding control signal.
13. The method of claim 10, wherein the automated welding device further comprises: at least one position adjusting module in one-to-one correspondence with the at least one welding head; before the position detection module detects the initial position of the welding head before welding and the welding position after welding, the method further comprises the following steps:
the position adjustment module adjusts the welding head to the initial position.
14. The method of claim 10, wherein the automated welding device further comprises: a positioning detection module; the output end of the positioning detection module is connected with the input end of the main control module; before the position detection module detects the initial position of the welding head before welding and the welding position after welding, the method further comprises the following steps:
the positioning detection module is used for carrying out positioning detection on the position of the welding head before welding and sending a positioning detection result to the main control module;
and when the position of the welding head deviates from the initial position, the main control module sends a positioning control signal to the welding head control module so that the welding head control module controls the welding head to move to the initial position.
15. The method of claim 10, wherein the automated welding device further comprises: a positioning detection module; the output end of the positioning detection module is connected with the input end of the main control module; after the main control module determines the welding result of the welding head according to the initial position and the welding position, the method further comprises the following steps:
the positioning detection module is used for carrying out positioning detection on the position of the welding head after welding and sending a positioning detection result to the main control module;
and the main control module determines the welding result of the welding head according to the position of the welding head after welding.
16. The method of claim 10, wherein the automated welding device further comprises: a display module; the input end of the display module is connected with the output end of the main control module; after the main control module determines the welding result of the welding head according to the initial position and the welding position, the method further comprises the following steps:
and the display module receives and displays the welding result, the initial position and the welding position sent by the main control module.
17. The method of claim 10, wherein the automated welding device further comprises: an alarm module; the input end of the alarm module is connected with the output end of the main control module; after the main control module determines the welding result of the welding head according to the initial position and the welding position, the method further comprises the following steps:
and when the welding height difference between the height of the initial position and the height of the welding position is smaller than the preset height difference, the alarm module receives an alarm control signal sent by the main control module and gives an alarm according to the alarm control signal.
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| CN112676676A (en) * | 2020-12-16 | 2021-04-20 | 武汉逸飞激光股份有限公司 | Tab welding method |
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Address after: No. 199, deer mountain road, Suzhou high tech Zone, Jiangsu Province Applicant after: CSI CELLS Co.,Ltd. Applicant after: CANADIAN SOLAR MANUFACTURING (CHANGSHU) Inc. Applicant after: Atlas sunshine Power Group Co.,Ltd. Address before: No. 199, deer mountain road, Suzhou high tech Zone, Jiangsu Province Applicant before: CSI Cells Co.,Ltd. Applicant before: CANADIAN SOLAR MANUFACTURING (CHANGSHU) Inc. Applicant before: CSI SOLAR POWER GROUP Co.,Ltd. |
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Application publication date: 20200512 |